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User Manual - Electronics For Industry, inc

1. Pressure 2 5 10 15 25 50 75 100 150 e e e e e e e e 125 psig e Trap psig psig psig psig psig psig psig psig psig PIPE SIZE Assigned orifice size in the steam trap styles and sizes per differential operating pressures as shown 1 2 1 4 l A 1 4 1 4 1 4 7 32 7 32 7 32 7 32 Dollar Loss Month 22 32 40 48 65 81 112 143 175 151 PO 3 4 5 lo 5 16 5 lo 5 16 5 16 1 4 A 1 4 A Dollar Loss Month 34 50 63 76 101 106 147 187 229 206 9 32 1 3 8 3 8 3 8 3 8 3 8 5 16 5 16 5 16 5 16 Dollar Loss Month 48 72 91 109 145 165 229 294 357 341 NOTE THE DOLLAR COST FIGURES SHOWN ON ALL THESE CHARTS REFLECTS THE COST OF STEAM IN THE 1980 S 12 DOLLAR LOSS TABLE FOR FLOAT AND THERMOSTATIC TRAPS Steam cost 6 00 1000 Ibs Float amp Thermostatic F amp T traps are found where higher levels of condensate are produced Unit heaters end of mains heat exchangers etc The modulating control provided by the float allows for continuous discharge of condensate when necessary The air vent in this trap will generally fail open after three to five years of hard work The mechanism and float assembly which allows the condensate to discharge may operate efficiently for eight to ten years and will normally fail closed after this time However sludge and debris accumulation may cause the assembly to fail open and waste big b
2. When valve movement changes due to leakage or sticking the sound pattern changes Each condition has ultrasonic components that can be sensed and monitored by the Microsonic detection unit Due to the short wave high frequency nature of ultrasound the sounds produced by a compressor valve can be isolated which provides a clear test result Detection Method For the contact method touch the valve with the contact probe and reduce the sensitivity until it 1s possible to obtain a meter swing around mid line and hear the valve open close movement When testing be sure to compare similar valves to each other 1 e intake to intake exhaust to exhaust and under the same conditions i e idling vs working For additional localization use the scanning module with rubber focusing extension Pressure amp Vacuum Systems Compressed air and gas Oxy Nitrogen LNG CNG etc and vacuum systems are easily checked for leaks or system flow Fittings valves couplings regulators hoses piping auto bleeders pneumatic actuators gaskets amp seals etc are among the system components easily checked Ultrasound is produced by the passage of air or gas though an orifice under pressure or vacuum The ultrasonic signature 15 heard by our detectors and converted into a sound you can hear through headphones and seen as an indication on an analog meter Detection method simply scan detector along system components pipe valves connectors etc until
3. operate e The size of the hole in the condensate discharge seat along with the steam pressure determines the trap s capacity to discharge condensate Lower pressure steam traps have larger condensate discharge holes than higher pressure rated steam traps 56 STEAM TRAPS INVERTED BUCKET TRAP INVERTED BUCKET TRAPS Depend on a water seal and weep hole for operation Because they discharge condensate intermittently they can be noisy PLACE PROBE ON TRAP AS SHOWN 57 STEAM TRAPS INVERTED BUCKET TRAP C DETAILED I B TRAP OPERATION The operating characteristics of the trap vary according to the condensate load 1 LIGHT LOAD BO gr The trap will dribble condensate without Wa 100 any distinct cycle Indicator will show only T very slight back and forth movement at the extreme lower end of the scale 2 MEDIUM LOAD The trap will open and close intermittently with a distinct cycle 3 HEAVY LOAD The trap will discharge condensate continuously This is usually observed at start up of equipment If trap does not catch up with the load and commence intermittent discharge this is an indication the trap is undersized for the application Continuously discharging under heavy Will register high on the scale with some back and forth movement of the indicator 58 STEAM TRAPS INVERTED BUCKET TRAP D BASIC I B TRAP OPERATION NORMAL LOAD NOTE Backgroun
4. 000 per year based on reducing 450 p s i steam consumption by about 1 000 Ib hr Chevron USA Perth Amboy NJ has six to eight thousand steam traps throughout the plant The plant generates close to 500 000 Ib hr of steam A steam trap audit revealed the trap failure rate was up to 28 The refinery has increased its steam trap reliability by 15 within two years after ultrasonic testing was put into use The reduction in steam losses is savings at least 50 000 a month Indiana University Perdue University campus at Indianapolis has three to four thousand steam traps Technicians using the ultrasonic testing to monitor steam traps and by pass valves estimate they are saving 300 000 per year AIR LEAKS In a 75 p s i system with a production cost of 0 14 m cu Ft a number of leaks totaling 1 4 will cost 5 734 15 in a year Double that to 1 2 and the cost of wasted air will be 22 940 25 In a 100 p s i system based on nozzle coefficient of 65 and a production cost of 0 10 per thousand cubic feet a number of leaks totaling 1 8 will result in the loss of 740 210 cubic feet of air per month at a cost of 74 01 per month Triple that to 3 8 and the waste will be 6 671 090 cu Ft per month and 667 19 An electronics components company estimated ultrasonic testing would be instrumental in saving them 25 per day in the cost of operating two 250 cfm air compressors at 110 p s i and eliminate the immediate need to purchase an
5. 300 Ultrasonic Stethoscope Contact Probe Aluminum case Single adjustment for A ff sensitivity vol Audio output to headset OM sensitivity volume PC sound card or tape 13 KIT CONTENTS MODEL W 7 Microsonic Detection Kit consists of the Pistol Style Detector Leak Detection Plug in Module Stethoscope Plug in Module Rubber Focusing Extension Tone Generator Deluxe Headset Carrying Case Stethoscope Sensitivity amp Meter Adjust tools This manual on a CD and batteries MODEL W 5 Nind Noise Test Set consists of the El 500 Tubular Style Detector Tone Generator Rubber Focusing Extension Headset Specify Light Weight or Deluxe and carrying case or carrying pouch depending on which headset option is selected INDIVIDUAL DETECTOR UNITS MODEL 7011 Microsonic Leak Detector consists of the Pistol Style Detector with a Leak Detector Plug In Module and Deluxe Headset MODEL EI 701S Microsonic Stethoscope consists of the Pistol Style Detector with a Stethoscope Plug In Module and Deluxe Headset MODEL 500 Microsonic Leak Detector consists of the Tubular Style Leak Detector a Headset Choice of Light Weight or Deluxe and a carrying case if the Deluxe Headset is chosen or pouch if the Light Weight headset is chosen MODEL EI 300 Microsonic Stethoscope consists of the Tubular Style Stethoscope unit a Headset Choice of Light Weight or Deluxe and a carrying case if the Deluxe Headset is
6. 638 40 1 127 20 1 772 90 2 560 90 Loss per Year 50 40 211 00 481 00 846 00 1 904 00 3 389 00 7 661 00 13 526 00 21 275 00 30 731 00 DIAMETER OF LEAKS Cu ft DAY AIR LOSS DOLLARS LOSS DAY DOLLARS LOSS MONTH DOLLARS LOSS YEAR 1 32 inch 1 6 inch 1 8 inch 1 4 inch 3 8 inch 1 2 inch 1 764 7 100 27 486 112 233 251 950 448 933 25 1 00 3 85 15 71 35 27 62 85 7 50 30 00 115 44 471 38 1 058 10 1 885 52 91 25 365 00 1 405 25 5 734 15 12 873 55 22 940 25 Costs based on 75 psi Syst at a production cost of 0 14 MCF with a run time of 8 760 Hours Year These charts do not address the cost of premature compressor wear or replacement incurred from additional run time to accommodate air leakage 82 AIR AND NITROGEN LOSS CALCULATIONS 555 Loss Per Year 20 57 A P Dg T 460 0 5 1000 60 8760 cost 1000 cu ft Dollars 55 lost per year based on effective leak size and pressure AREA SYSTEM PRESSURE ISIG PI R 2 SEE i 30 45 100 450 _ 0 000767 sims 3242 _ j 10544 501088 3105442 38 0 003068 37491 1 249 69 1 874 53 3 _ 8454 s2B1 90 421z69 SIZ E RENVESTMENT A ROI based on 0 65 1000 cu ft product 28 vears ROI based on 45 psi system pressure lt a Assume valve packing leaks RS Assume 1 2 to 1 valves Assume air service Assume 1
7. CAULKING amp DRIP CHECK ULTRASONIC TESTING CAN SAVE TIME amp MONEY BY QUICKLY LOCATING SQUEAKS amp RATTLES BEARING NOISES EXHAUST LEAKS DAMAGED BELTS VACUUM LEAKS INTERNAL ENGINE TRANSMISSION amp DIFFERENTIAL WEAR or DAMAGE Until the advent of ultrasonic testing leak detection could involve hours of trial and error with the use of water testing bubble testing tracing fluids or compressed air and powder often requiring two technicians for hours Frequently the results of these efforts were less than satisfactory Ultrasonic testing 1s fast simple and accurate Saving time money and resources while insuring customer satisfaction REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 103 NEW amp TRUCK DEALERSHIP gt SERVICE DEPARTMENT gt BODY SHOP gt FACILITY MAINTENANCE SERVICE DEPARTMENT Ultrasonic testing as a quality control procedure during repair and as quality assurance during a pre delivery inspection can have a significant affect on customer satisfaction Ultrasonic testing when shown to customers will also promote customer confidence and shop credibility e AIR AND WATER LEAKS INTO PASSENGER OR TRUNK AREAS e DOOR WINDOW FLOOR amp ROOF SEALS FOR WATER AIR OR EXHAUST ENTRY POINTS EXHAUST SYSTEM FOR LEAKS SQUEAK AND RATTLE LOCATION NEW VEHICLE PRE DILIVERY INSPECTION VACUUM SYSTEMS FOR LEAKS ENGINE INTERNAL DIAGNOSTICS DRIVE LINE DIAGNOSTICS BEARINGS FOR EXCESSIVE WEAR H
8. FIX IT FIRST YOU HAVE TO FIND IT 100 ULTRASONIC DRY PIPE FIRE SYSTEM SURVEY Ultrasounds by definition are beyond the limits of normal human hearing Using a sophisticated detector a technician is able translate ultrasonic signals to the range of human hearing The theory of ultrasonic detection is relatively simple Frequency the number of times a sound wave cycles from trough to crest is expressed in cycles per second and measured in hertz One kilohertz is 1000 cycles per second Human ears can generally hear noises in the range of 20 to about 20 000 Hz 20kHz EFI ultrasonic detectors start at approximately 20 kHz and can work upward to sound as high as 100kHz Thus Technicians using the ultrasound instrument can tune to and hear what is going on in operating machinery and pressurized systems When a leak occurs the fluid or gas passing through produces turbulence with strong ultrasonic components Higher frequency sounds cannot penetrate most solids yet they slip through the tiniest of openings Ultrasound detectors are ideal for isolating such leaks The pistol shaped Microsonic detection unit is battery powered and lightweight Operators can easily leak test large sections of piping quickly and effectively Leaks in pressurized Dry Pipe systems are found by simply sweeping the Microsonic detector over the area to be checked Ultrasound generated at the leak source is made audible in the headphones and visible on the u
9. This is similar to the way radios convert radio waves to audible sound We all know that a gas air leak generates noise sometimes we can hear it Whether we can hear it or not depends on many factors Some of those factors are the amount of other noise in the vicinity to mask it the size of the leak characteristics especially the size and shape of the hole that allows the leakage the type of material and the pressure that forces the gas out of the hole Leaks generate ultrasonic noise as well as noise that we can hear with our ears The problem with listening for leaks is that our ears are not sensitive enough especially for small leaks They are not very directional due to their 20 design and purpose Another problem is that there is almost always some normal or machine noise in the vicinity which would mask the leak source sound Using a leak detector to listen for the ultrasonic signature of a leak is far superior to using our ears to locate leaks Ultrasonic detectors can be made much more sensitive than the ear to detect leaks Ultrasonic noise is also much more directional making it easier to find the leak vicinity move closer and then pinpoint the source In general there is not much ultrasonic background noise to mask the leak noise If there are other sources of ultrasonic noise they are usually widely enough scattered to be unimportant since ultrasonic noise is absorbed much more as it passes through a distance in a
10. chosen or pouch if the Light Weight headset is chosen There are several accessory items that are available such as TTG 2 Tubular Tone Generator for inserting a tone into pipes or other such small opening spaces i H 1 Pistol Holster which allows the pistol detectors to be worn on a belt The holster has an additional pouch so that a second module may be stored in it MSM 1 Magnetic Stethoscope Module A module that plugs into the front end of the Pistol Style Detector with a five foot cord leading to the actual Stethoscope Module which has a y rare earth magnet assembly on the front to allow it to be magnetically attached to the piece of machinery 3 being listened to This is especially useful when the operator needs both hands free such as when using a grease gun to inject grease in a bearing and listening for the lowest sound point which indicates the optimal grease point PK 1 Probe Extension Kit Three 12 inch extension rods to extend the reach of the Stethoscope units Technical Specifications Item Weight Housing Length Width Power Pistol Style Detector 1 5 Lbs Plastic 8 2 75 1 9V Leak Detector Molded Module LDM 1 23 In xs Stethoscope Molded T Module SM 1 1 502 Nylon 6 35 1 5 N A TG 2 Tone Generator 6 3 oz ABS T1000 Plastic 5 5 2 5 4 1 5V Rubber Focusing Rubber Extension RFE 1 Ed 06 Polymer Mix ni me Probe Extension Kit PK 1 2 5 OZ Aluminum 12
11. compressed air systems We use the internet to deliver information about the best people and companies in the compressor business http www oit doe gov bestpractices steam Government steam systems resource site VERY GOOD http www oit doe gov bestpractices compressed_air Government compressed air resource site VERY GOOD http enerchecksystems com index html Complete ultrasonic Dist Mfg good how to site http www amgas com ldpage htm American gas amp chemical Co Ltd Leak detection technology http leakzone com Large leak detection resource site http steamlink com 1wdm html Steam trap resource site http uesystems com Competing ultrasonic equipment Mfg good resource for applications how to information http Awww maintenanceresources com reterenceLibrary ezine ultrasonic htm Ultrasonic testing procedures for steam traps http knowpressure org The Compressed Air Challenge is a voluntary collaboration of industrial users manufacturers distributors and their associations consultants state research and development agencies energy efficiency organizations and utilities http www e4i com Web site for Electronics For Industry Inc 105 SECTION 14 ADDENDUM LAST MINUTE CHANGES AND ADDITIONS 106 The End Please visit our Web Site www e4i com Thank You 107 108
12. control valve exhaust port Pipefittings may be loose because equipment has been improperly installed or because sealant was improperly applied during installation Poor quality materials also can be a cause In other instances the location of the piping causes a leak If a pipe connection is bumped occasionally by lift trucks pallet jacks or other material handling equipment the fittings may become cracked Sometimes leaks are the result of human error Workers may leave leaking tools on often beyond the inlet air isolation valves or neglect to close valves and halt the supply of air when there is no need for a particular application or when production is shut down The audit Any manufacturing plant will benefit from a compressed air system audit Typically production demands account for only 50 percent of the total demand for compressed air the remainder is lost An audit pinpoints all air leaks An audit at a small manufacturing plant revealed that the company was spending about 34 000 year to run two air compressors if they had repaired the air leaks they could have run just as efficiently with one compressor Ata larger facility an audit showed that repairing all air leaks would reduce the demand for air by approximately 900 scfm and save about 70 000 year It is also important to identify uncontrolled demand and improper pressure regulation and to address poor applications for air including conventional blow off Auditors
13. evaluate the system s distribution and storage systems and review specific problem areas They also evaluate the operation of all air compressors determine the need for additional equipment or controls measure energy demand and judge energy use The auditors thoroughly check all equipment tagging leaks and noting their locations on a worksheet 79 and provide a list of materials needed to fix the equipment The audit concludes with a report listing operating costs the cost of improvements projected savings and a plan to achieve successful results Maintenance professionals who pay close attention to the air leak audit quickly learn how to keep their plants operating efficiently They assign maintenance crews to fix all leaks and go back through the facility to retest all the problem areas An ultrasonic detector is the best tool for the job FINANCIAL RESULTS AND SAVINGS In one plant repairing 324 air leaks lowered the demand for air an average of 750 cfm on the first shift 475 cfm on the second shift and 425 cfm on the third shift and Saturdays The air leaks cost 52 304 year Eliminating uncontrolled demand through proper pressure regulation lowered the demand by an average of 570 dfm on the first shift 330 cfm on the second shift and 280 cfm on the third shift and Saturdays Uncontrolled demand cost 37 008 year Installing high efficiency air amplifying blow off nozzles and eliminating or controlling questionable applica
14. headset and there will be a rise in the meter reading The closer you get the louder it will be until you reach the source as you pass it the sound diminishes You have now pinpointed the problem Repair it and check it again repair more if needed but you never need to wet the car All searching and repairing is done while the vehicle is dry No road testing for Wind Noise problems Boats Easily find where the water is entering around windows portholes and hatch covers Hull leaks and seals are quickly checked using the Microsonic Detectors 31 Boilers and Heat Exchangers Boiler tube leakage or blockages can be heard by listening on the outside of the shell in the vicinity of the tubes Leaking or blocked tubes generate a different sound than normally operating tubes Heat exchangers of all kinds can be tested using the Tone Generator The tone generator is set to impinge its energy on the outside of the tubes and the Microsonic Detector is used at the tube ends to listen for the tone that will be heard where there is a holed or leaking tube If the leak is around the end roll then the tone will be heard around the periphery of the tube in question Use of the Rubber Focusing Extension is recommended to make pinpointing easier For very large heat exchangers the use of multiple tone generators to create a higher level of energy around the tubes is recommended Compressors and Pneumatics Pinpoint leaks in pneumatic
15. or disassembly The accuracy of results will improve in a direct relationship with the experience gained through continuing usage 45 MAINTAINING STEAM TRAPS Failed steam traps waste energy and adversely affect product quality Therefore a maintenance program for steam traps is a good investment Most plant and facilities professionals with steam systems in their care have asked questions like the following e What are the signs of a malfunctioning steam trap e What inspection techniques are available e What testing instruments should we use e How do we start a steam trap maintenance management program e What kinds of training resources are required Steam Trap Basics Basically all steam traps have the same function They allow condensate and non condensable gases to escape while holding steam in a device where a thermal or heat transfer process occurs A regulator controls the input side of the process and the steam after releasing energy to the process condenses and reverts back to its liquid state The purpose of the steam trap is to retain steam in the heating element and to release the non condensable gases and condensate The principal design consideration is to balance the condensing rate and the import rate of the control device on the input side with the exiting condensate Stephen Banyacski president of Nicholson Steam Traps Walden New York emphasizes the need to choose the appropriate steam trap Prope
16. rubber focusing extension over the detector module and scan the test area Listen for a rushing sound while observing the meter Follow the sound to the loudest point The meter will show a higher reading as the leak is approached In order to focus in on the leak keep reducing the sensitivity setting and move the tool closer to the suspected leak site until you are able to confirm the exact leak point To confirm a leak position the rubber focusing extension on the leak detector module close to the suspected leak site and move it slightly back and forth in all directions If the leak is at this location the sound will increase and decrease in intensity as you sweep over it In some instances it is useful to position the rubber focusing probe directly over the suspect leak site and push down to seal it from surrounding sounds If it is the leak the rushing sound will continue If itis not the leak site the sound will drop off 4 Wrapping a shop rag or towel around the detector and rubber focusing extension can also help block interfering ultrasonic noises 5 Another method is to put the shop rag over the suspected leak creating a void over the leak Insert the end of the rubber focusing extension on the leak detection module into the area of the suspected leak The area will be isolated from the surrounding ultrasound thus making pinpointing much easier Sometimes a gloved hand can create the same effect SAFETY FIRST ALWAYS AVOID AN
17. sensitivity and continue to follow to the loudest point REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 94 TRANSPORTATION amp EQUIPMENT ULTRASONIC INSPECTION a Y DESCRIPTION The most common areas for ultrasonic inspection in the transportation industry are wind noise water leaks air brakes and emission systems Until the advent of ultrasound water leak and wind noise detection involved many hours of trial and error with a water hose and flashlight Often a few trips around the block listening with a doctor s stethoscope for a wind noise captured two people for many hours Air brake leaks and emission leaks can take hours to locate using conventional soap and water bubble testing Not only can service shops benefit from Ultrasonic Inspection so can Quality Assurance departments by providing accurate fast and simple testing How Ultrasonic Detection Works Compressed gases when leaking produce a turbulent flow with strong ultrasonic components By scanning fittings a leak will be heard as a distinct hiss Due to the high frequency short wave nature of ultrasound the sound will be loudest at its point of origin The Microsonic unit translates the ultrasonic leak signals into recognizable audible signals where they are heard through headphones and seen as intensity increments on a meter A unique test incorporates a patented ultrasonic transmitter called a Tone Generat
18. tend to propagate more directionally like a beam This makes the location easier to pinpoint As the wave frequency increases it becomes more and more attenuated by distance requiring the detector to be closer to the source or more sensitive to hear the vibration Leak Testing Objectives Like other forms of nondestructive testing leak testing has a great impact on the safety or performance of a product Reliable leak testing saves costs by reducing the number of reworked products warranty repairs and liability claims The time and money invested in leak testing often produces immediate profit The three most common reasons for performing a leak test are 84 1 MATERIAL LOSS With the high cost of energy material loss is increasingly important By leak testing energy is saved not only directly through the conservation of fuels such as gasoline and LNG but also indirectly through the saving of expensive chemicals and even compressed air 2 CONTAMINATION With stricter OSHA and environmental regulations this reason for testing is growing rapidly Leakage of dangerous gases or liquids pollutes and creates serious personnel hazards 3 RELIABILITY Component reliability has long been a major reason for leakage testing Leak tests operate directly to assure serviceability of critical parts from pacemakers to refrigeration units MECHANISMS THAT PRODUCE ULTRASOUND A number of different mechanisms produce translatable ultrasonic
19. the Stethoscope Module itself by adjusting the potentiometer located in the module itself Use the screwdriver supplied with your kit to turn down the control through the hole on the side of the module until the meter remains on scale The Microsonic Stethoscope will detect internal sounds in the ultrasonic range It does not detect the sounds that the ear can hear or other low frequency sounds such as a heartbeat The friction between moving parts of machinery generates ultrasonic sound As a general rule the ultrasonic sound is very similar to the low frequency sound heard by your ears a mirror image but displaced in frequency If you touch the probe to the case of a mechanical watch for example the ticking sound is similar to that heard with the unaided ear The sound from the stethoscope however has much better definition Minute sounds are present that was not noticed before The stethoscope is detecting sound generated by the friction of the parts rubbing together and not just the clicking sounds of the escapement or gear wheels meshing As wear begins in machinery ultrasonic sound from increasing friction is building up long before the unaided ear can hear it The Stethoscope is valuable because of this It forewarns you The repair or maintenance can be carried out at a more convenient time rather than waiting for failure that always occurs at the most inopportune time Furthermore damage is often more severe during late
20. this type construction is diagrammed below Folded Seams eise OMA FUA iar D Li a eee p d o hi E z e Ol D ef as D Bra i RM E A E E AAA E A A r UN UR E NUR shee HOSUR RE war S ial al a ial tad ee ee w A a al at al Tar at Th Ta Lu i T OC P at o A situation somewhat related to the faucet threaded fitting condition is found in searching for leaks in a vacuum system More noise generating turbulence exists inside the chamber than out because the high pressure area is outside The outside air is forcing its way through the hole into the lower pressure area inside Detectors on the outside can still be very useful even in this adverse situation since turbulence will exist at the entrance point A quick example of the sensitivity of the leak detectors is to put on the headset and turn on the detector Hold your free hand a few inches away from the front of the detector and gently rub your thumb and forefinger tips together The noise you hear is friction generated ultrasonic noise converted 22 down to the audible sound A similar example is to hold the detector opening a couple inches from one eye and then blink the eye rapidly The friction of the eyelashes rubbing together generates the noise Yet the detector does not react to ordinary sound in the vicin
21. warning signals to be detected before actual equipment failure occurs According to plant manager Perry Sterner using ultrasound we have the choice of testing for bearing wear either during actual production or when the plant is shut down Wherever there is evidence of a problem says Sterner we use the ultrasonic detection tool to provide confirmation of our vibration readings and replace the faulty bearing One of our biggest problems is dry bearings Using the ultrasonic detector we can hear if the bearing is running dry or if there is a small particle of dirt on the ball If there is a flat spot on the ball hitting the raceway of the bearing we ll hear it randomly as the ball rotates Sterner schedules periodic greasing of the bearings and can listen with the ultrasonic equipment as he pushes grease into the raceway The meter readings are recorded monthly and are used to indicate when the bearings need to be replaced In addition to using the ultrasonic detector for predicting and preventing bearing failure Inland Empire Foods periodically checks for leaks in steam traps inspects motors for phasing problems and checks starters for arcing with the sensitive listening equipment Recently Sterner discovered another use for his ultrasonic detector Our QC department had placed a load of black eyed peas on hold for possible infestation and disposal was curious to know if the ultrasonic device could detect the presence of insect
22. 00 per valve repair Density of Nitrogen 0 0724 Density of Air 0 07494 Temperature T 70 F Density Dg 0 07494 air Cost Per 1000 cu ft 50 65 3 8 months e months 1 tij Prepared by Team I 83 SPEECH GIVEN AT MEETING OF NON DESTRUCTIVE TESTING SOCIETY THERMOGRAPHICS LIGHT SIGNATURE YOU CANNOT SEE VIBRATION ANALYSYS VIBRATION SIGNATURE YOU CAN NOT FEEL ULTRA SOUND SOUND SIGNATURE YOU CAN NOT HEAR As the name Ultrasonic implies this term deals with that branch of acoustics whose frequency waves are above the highest frequency audible to the human ear Ultrasonic vibrations Sound Waves are measured in terms of Hertz Hz One Hz is one wave cycle per second The human ear is generally assumed to hear sounds with a frequency of 16 Hertz up to a limit of 20 Kilo Hertz 20 000 cycles per second However most sounds which we hear are in a very limited range considerably below this theoretical limit Today the most generally accepted definition of Ultrasonics refers to sound waves with a frequency greater than 16 Khz The present upper limit of detectable ultrasonic frequencies is approximately 100 Mega Hertz 100 000 000 cycles per second As the frequency of the sound wave changes the way in which the sound wave propagates also changes Low frequency sounds tend to propagate spherically with equal intensity in every direction Higher frequency waves particularly those over 20 kilohertz
23. 15547 207 29 259 41 621 87 829 16 1 036 45 Prepared by Team Inc RETURN ON YOUR INVESTMENT 1 64 18 0 months 3 64 20 months 1 20 728 95 Eas 1 0 months 7 80 14 575 04 S25 911 18 Assume valve packing leaks 5 Assume 1 2 to 1 valves Assume steam service lt 150psi Assume 5100 per valve repair 52 59 1554671 51299 56 95 102 24 11 660 08 20 725 95 75 SECTION 10 BENEFITS BENEFITS OF THE TOOLS THE HIGH COST OF PROCRASTINATION Estimates of loss year costs of air and Nitrogen have become staggering The cost savings of the relatively simple project of repairing leaks are tremendous The estimated cost per year of on 1 8 air leak is 2 980 00 If only one 1 8 air leak was assumed for each of the main plant areas the total annual loss cost would be approximately 23 840 00 Nitrogen leaks are even more expensive events One Nitrogen leak of only 1 16 costs a whopping 10 700 00 est per annum If we use the air leak scenario for the 1 16 Nitrogen leak the loss cost would be almost 75 000 00 A larger tank such as a broken 1 4 OD instrument line will cost a plant 270 00 per day THAT S OVER 90 000 00 per year in Nitrogen for ONE leak Total savings of nearly 1 000 000 00 annually just for repairing fourteen or so small leaks a fair return There are likely more than that when one considers the total number of possible leak sour
24. 230 08 1640 10 s2050 i3 5246015 100 1 640 10 5218580 5273350 Trap Population 1000 Dollars 595 Lost Per Year FAILURE TRAPS FAILED OPENED 10 s 6833755 136 675 10 205 012766 5273 250221 45 102 508 53 205 012 66 8 iB 410 025 31 20 1366 8 0 s273 35021 410 025 31 546 700 47 170 843 88 8341 687 76 512 531 64 683 375 52 30 205 012 66 410 025 31 615 037 97 820 050 62 Le Assume 2 500 raps ith a 2056 tallirta Steam cost at 55 00 oer 1 Gug Lo Assume 18 blow through or loaking example based on a 2 500 trap population you have 2 500 aps assume Assume 75 effective average opening fallin rale ol 1575 neg ail taps do not faul at 1002 oped sssume failure rate Assume 375 traps need ta be replaced at 755 oben Your estimated steam losses then Would be 6 407 518 88 X 2 5 adjusi Assume all rans in tracer service rent for trap population size or 758 97 45 per year As simae 2505 per trap rapal Cont Prepared by Team Inc STEAM RETURN ON YOUR my IMVESTMENT 4 0 months 25 months z STEAM LEAK LOSS CALCULATIONS Modified Napier Formula PL R2 X SP X 51 42 X 8760 1000 X cost of steam 1000 Ibs ORIFICE 5 00 6 00 cies s49 20 5589 00 Dollars Lost Per Year Per Leak Cost Per Thousand Pounds Of Steam Using 150 1b Steam
25. 6 105 131 158 344 478 150 180 241 392 544 Orifice 100 psi 125 psi 150 psi 200 psi 250 psi 300 psi Diameter 1 32 2 7 3 9 531 7 4 1 16 10 8 15 6 29 8 3 32 24 4 35 1 67 0 1 8 43 4 62 4 100 119 5 32 67 9 97 4 127 156 186 3 1 97 7 140 183 226 268 7 32 133 162 191 249 307 365 1 4 173 212 250 325 401 77 9 32 220 268 316 412 507 603 5 16 272 331 390 508 327 745 11 32 329 400 472 615 758 901 3 8 391 476 561 732 902 1073 13 32 459 559 659 859 1259 7 16 532 648 764 996 1228 1460 1144 15 32 611 744 877 1144 1410 1676 1 2 695 847 998 1301 1604 1907 FAILED STEAM TRAP DOLLAR LOSS TABLE FOR RADIATOR TRAPS Steam Cost 6 00 1000 Ibs Pressure balanced thermostatic radiator traps are most commonly found on low pressure 25 psig and under steam heating systems Located on radiators convectors and other radiant heat units there may be literally hundreds of these scattered throughout larger facilities The operating unit within the trap a pressure balanced disc or bellows is filled with a distilled liquid to respond to the changes in temperature i e pressure within the trap The disc or bellows will generally fail open after three to five years of hard work after five years it has opened and closed hundreds of thousands of times The orifice sizes shown for all the steam traps are conservative estimates of the average size found in these traps Actual dollar loss may be more or less than shown
26. CHNICAL SPECIFICATIONS page 15 WARRANTY AND REPAIR INFORMATION 16 CERTIFICATE OF CALIBRATION page 17 SECTION 3 INTRODUCTION TO ULTRASOUND 18 INTRODUCTION TO ULTRASOUND pages 18 to 22 ULTRASONIC LEAK DETECTION 23 amp 24 INTERFERENCE SOURCES AND SOLUTIONS 24 COMMON SOURCES OF INTERFERENCE 26 ADVANCED DETECTION METHODS AND STUBBORN LEAKS page 27 SECTION 4 USES amp APPLICATIONS 28 USES AND APPLICATIONS FOR THE ULTRASONIC TOOLS pages 28 to 34 SECTION 5 MECHANICAL ULTRASONICS 35 ROTATING EQUIPMENT pages 35 to 38 GEARS PUMPS AND MOTORS pages 39 to 41 SECTION 6 ELECTRICAL 42 ELECTRICAL EQUIPMENT ANALYSIS USING ULTRASOUND 42 44 SECTION 7 STEAM TRAPS AND VALVES 45 to 50 STEAM TRAPS GENERAL EVALUATION TESTING AND MAINTENANCE OF STEAM TRAPS VALVES SECTION 8 STEAM TRAPS IN DETAIL 90 to 70 SPECIAL SECTION ON STEAM LOSS TRAP ANALYSIS AND READINGS USING THE ELECTRONICS FOR INDUSTRY Inc PISTOL TYPE DETECTOR SHOWING TYPICAL METER READINGS AND SOUND PATTERNS SECTION 9 STEAM LOSS AND COST CHARTS 711075 COST OF STEAM TABLES AND CHARTS SECTION 10 BENEFITS OF THESE TOOLS 76 to 87 TOOL COST AND PAYBACK ANALYSIS AIR LEAK CHARTS PLUS A SPEECH GIVEN AT AMER SOC OF NON DESTRUCTIVE TESTING SECTION 11 FEATURES AND PRICE COMPARISONS 88 COMPETITIVE EQUIPMENT COMPARISON AND PRICING SECTION 12 SPECIFIC USES AND APPLICATIONS 89 to 104 PRINTABLE SHEETS FOR INDIVIDUAL APP
27. D Example of a qgood valve Leak Detection Method Inspection methods vary depending on the type of valve or steam trap Therefore the primary rule is to know the details of your system for example the way a specific trap or valve may work under specific conditions In order to determine leakage or blockage touch upstream of the valve or trap and reduce the sensitivity of the instrument until the meter reads about 50 If it is desirable to hear the specific sound quality of the fluid simply tune the frequency until the sound you would expect to hear becomes clear It s that simple Next touch downstream of the valve or trap and compare intensity levels If the sound 15 louder down stream the fluid 1s passing through If the sound level is low the valve or trap is closed Ultrasonic valve and steam trap inspection is considered a positive test in that an operator can instantly identify sound quality and intensity differentials and thereby determine operating condition accurately REMRMBER TO FIX IT FIRST YOU HAVE TO FIND IT 03 PIPE JOINTS VAULTS VALVES amp TANKS ULTRASONIC INSPECTION DESCRIPTION Pipe is the heart of any gas or liquid distribution system Inspection and maintenance can prevent unplanned leaks and downtime Any type of pipe can be inspected ultrasonically Concrete PVC PE Steel Iron Aluminum Copper Fiberglass Filament Wound Etc DON T BURY A LEAK Ultrasonic testing 1s done duri
28. Detect amp locate corona affecting electronics Detect amp locate arcing amp sparking in electrical systems Locate vacuum and static system leaks Detect instrument face leakage Detect which gyroscopic instrument is starting to fail How Ultrasonic Detection Works Operating systems such as compressed gas systems valves motors pumps etc all produce ultrasound Some high frequency sounds are generated from turbulence others from friction As components begin to wear fail or leak there is a change in the normal ultrasonic pattern This can be detected as an increase in amplitude a change in sound quality or a change in sound pattern Since ultrasound 15 a high frequency short wave signal it will isolate the signal by localizing the problems and detect subtle changes for early warning detection The Microsonic test unit detects minute changes in ultrasound and converts these signals so that they may be heard through headphones and observed as intensity increments on a meter By using plug in modules for either a scanning mode or a contact mode equipment may be inspected for leakage or for mechanical problems Due to its portability and its rating of Intrinsically Safe class 1 Division 1 Groups A B C amp D the Microsonic unit may be used all around the aircraft Detection Methods For general leak detection in a scanning mode move along the area to be tested with the sensitivity at high and using a slight waving motion l
29. Electronics For Industry INC ELECTRONICS FOR INDUSTRY INC DETECTION TOOLS Model EI 500 Leak Detector Model EI 300 Stethoscope Pistol Style Detector Used in Model W 7 Model El 701L Model EI 701S Electronics For Industry Inc 6850 SW 79 Terrace South Miami Florida 33143 4440 305 233 1640 voice 305 666 4185 fax sales e4i com e mail www e4i com web site Version NOV2010 User manual Introduction to and Applications For Ultrasonic Testing Ultrasonic Tools Their Uses and Applications Everything you always wanted to know about ultrasound and ultrasonic detection and probably a lot of stuff you really did not want to know INDEX SECTION 1 QUICK START This section is for those who are familiar with Ultrasound characteristics and have some familiarity with Ultrasonic Testing Tools If you are new to Ultrasound and Ultrasonic Testing Tools please first read the information on Ultrasound and Ultrasonic tools which can be found in later sections It is suggested that you read the detailed information sections before continuing and then return to the quick start instructions PAGE SECTION 1 QUICK START 5 PISTOL STYLE LEAK DETECTOR page 5 TUBULAR STYLE LEAK DETECTOR 6 TONE GENERATOR pages 7 amp 8 PISTOL STYLE STETHOSCOPE page 9 TUBULAR STYLE STETHOSCOPE SECTION 2 KIT DESCRIPTION AND OPERATION 11 GENERAL DESCRIPTION OF KITS page 11 KIT CONTENTS pages 11 to 14 TE
30. IX IT FIRST YOU HAVE TO FIND 102 COLLISION REPAIR INDUSTRY ULTRASONIC INS COME BACKS AND RE DO S LOST PROFIT amp LOST CUSTOMERS A major repair has been completed and everything is just right with form fit and finish reflecting your shops reputation for quality work Your customer comes in to take delivery inspects the repairs and expects all to be to pre accident condition All is well the repairs are paid for forms are signed and off drives another satisfied customer Most of the time this is how it goes On occasion a vehicle comes back with a concerned or irate customer complaining about some aspect of the repair they feel was not done properly and frequently the complaint will involve e A WATER LEAK AT THE REPAIRED AREA door trunk floor window e AN AIR LEAK AT THE REPAIRED AREA e A NOISE THAT WASN T THERE BEFORE Ultrasonic testing as a quality control procedure during repair and as quality assurance during a pre delivery inspection can have a significant affect on customer satisfaction Ultrasonic testing when shown to customers will also promote customer confidence and shop credibility ULTRASONIC TESTING CAN QUICKLY LOCATE AIR amp WATER LEAKS AT DOORS DECK LID SUN ROOF amp T TOP seals weather strips caulking rust FLOOR PAN ROCKERS WHEEL HOUSE REAR BODY PANEL caulking welds rust WINDSHIELD BACK GLASS amp SIDE GLASS seals amp weather strip Rust WEATHER STRIPS
31. LICATIONS AND USES SECTION 13 WHERE TO GET MORE INFORMATION 105 WEB LINKS TO PUBLISHED INFORMATION ON LEAK DETECTION AND LEAK DETECTORS SECTION 13 ADDENDUM 106 LAST MINUTE CHANGES AND ADDITIONS PLEASE CHECK HERE FOR ADDED INFORMATION SECTION 1 QUICK START OPERATION AS A LEAK DETECTOR Pistol Style Detector Insert the Leak Detection Module the one with the grill opening at the front into the recessed front of the Detector body Be sure that both connector pins line up with the receptacles and that the Module seats fully in the recess Plug the headset cord connector into the receptacle in the bottom of the grip of the gun You are now ready to search for leaks of any gas or vapor that is under pressure or vacuum To remove the Leak Detector module pull it straight out from the pistol body and store it in the storage slot in the die cut foam To search for leaks 1 Turn the Volume Sensitivity control located on the underside of the pistol just forward of the trigger all the way up a reading of 10 on the dial 2 Hold the unit as you would any gun 3 Depress and hold the trigger to turn on the detector 4 Scan the area of possible leaks with the muzzle of the gun A leak sounds like a rushing sound in the headset accompanied by an increase in the meter reading As you approach a leak the rushing sound becomes louder and the meter reading continues to increase scanning or sweeping back and forth moti
32. Microsonic Detectors do not hear sounds the normal ear hears so it is easy to pinpoint leaks even in a very noisy shop By pointing the front of the detector at the leaking flange or joint you will hear the rushing or hissing sound that indicates leak Be sure to check the threaded fasteners that hold the flange together it may be one of these leaking not the gasket In Manholes Steam pipes compressed air pressurized telephone cables are just a few of the many things that are run under the street that can develop leaks Many of these leaks can be heard by placing the front end of the Microsonic Leak Detector at the Pry hole of the manhole before even opening the manhole Once you hear the leak in the manhole then you can go into the manhole and pinpoint the tube pipe or cable that is leaking and then make repairs Hear unusual noises motors The Microsonic Stethoscope allows you to hear the noises from inside machinery without hearing all that is going on around you By contact the housing in the vicinity of the moving parts you will hear what is happening inside Is ita smooth normal sound ora rough intermittent or grinding sound Do you hear the brushes arcing Can you hear the brush holders dragging Is the shaft running true Pinpoint these and other problems at an early stage so you can plan maintenance and have the necessary parts ready Don t wait for an emergency breakdown and try and jury rig the rep
33. Y PERSONAL CONTACT WITH MOVING HOT COLD HIGH PRESSURE OR ELECTRICALLY CHARGED SURFACES 25 Common Sources of Interference Expansion Valves in high pressure refrigerant lines As the high pressure liquefied refrigerant expands to gas it can sound as if the entire surface of the expansion valve is leaking To find leaks in these systems it is generally better to shut the system down While the high pressure is in the lines make an immediate search for the leaks Glass bottles on conveyers Bottles rattling against each other on a moving conveyer line can generate very high intensity ultrasonic noise When searching for leaks in the vicinity of these lines it is often better to wait until the line is stopped or to make a sound proof test area by enclosing the test area with visquine Pneumatic equipment and tools Some air operated equipment regularly exhausts air which amounts to a large leak Try steps 1 2 3 above if this does not help you may have to wait until the interfering equipment is not in use Grinders Grinding machines and cutting wheels especially when cutting metal create large amounts of ultrasound Computers Computers are now found almost everywhere they are often in maintenance offices and sometimes on factory floors to control equipment or processes Some computers and some computer displays monitors generate ultrasonic noise Transformers in both sometimes operate at an electronic frequency comparabl
34. YDROLIC SYSTEM DIAGNOSTICS OF VALVES SEALS amp PUMPS FOR INTERNAL LEAKAGE DRIVE BELTS FOR CUTS amp CRACKS e REDUCE DIAGNOSTIC TIMES SIGNIFICANTLY BODY SHOP AIR amp WATER LEAKS AT DOORS DECK LID SUN ROOF REMOVABLE ROOF PANELS AIR amp WATER LEAKS AT WINDSHIELD BACK GLASS SIDE GLASS AIR amp WATER LEAKS AT SEALS CAULKING WELDS RUSTED PANELS LOCATE SQUEAKS amp RATTLES LOCATE EXHAUST SYSTEM LEAKS AND RATTLES DETECT DAMAGED ENGINE BELTS DETECT DAMAGED BEARINGS FACILITY MAINTENANCE e LEAK TEST SHOP COMPRESSED AIR SYSTEM MAJOR SAVINGS POTENTIAL o SEE ATTACHED CHART INDICATING COSTS OF COMPRESSED AIR LEAKS e LEAK TEST FACILITY DRY PIPE FIRE SUPPRESANT SYSTEM e LEAK TEST DOORS WINDOWS STORAGE AREAS Until the advent of ultrasonic testing leak detection could involve hours of trial and error with the use of water testing bubble testing tracing fluids or compressed air and powder often requiring two technicians for hours Frequently the results of these efforts were less than satisfactory Ultrasonic testing is fast simple and accurate Saving time money and resources while insuring customer satisfaction REMEMBER FIX IT FIRST YOU HAVE TO FIND IT 104 SECTION 13 WHERE TO GET MORE INFORMATION Resources with Web Links http compressorwise com CompressorWise com is an independent research and publishing company established to help compressor operators save money and get the most from their
35. additional compressor TE BEARINGS N Ren A bearing on one of their two 500 H P motors froze up and did 2 500 damage Using the stethoscope module they picked up a bad bearing noise on the second motor resulting in immediate repair and avoiding a complete shutdown in one area of the plant Anaconda Wire On a Saturday when the shop was shut down maintenance personnel used a regular stethoscope and picked up a bearing noise with the machine running at low speed The housing they listened to contained two bearings at a cost of 1 500 each Their stethoscope could not determine which bearing was going bad With the plant back in operation on Monday and all other machinery running ultrasonic testing was used to check the machine in question while running at top speed The ultrasonic test identified the front bearing as being the culprit while the back bearing was okay They immediately replaced only the front bearing at a cost of 1 500 and were back into production much sooner than would have been the case had they replaced both bearings BENEFITS OF AN IN PLANT AIR LEAK SURVEY BENEFITS AND METHODS OF AN IN PLANT AIR LEAK SURVEY Contrary to conventional wisdom air is not free In fact air costs more than water electricity or steam Air leaks slow down a plant s operation expending more power than necessary to supply compressed air and can lead to shutdown Uninformed maintenance practices are often the culprit F
36. air High pitched sound is absorbed more than low pitched sound Think about distant thunder We hear a low pitch rumble If lightning strikes nearby we also hear a crackle with the rumble The crackle is the high frequency portion of the noise The higher frequencies are often absorbed before reaching us Relative humidity is a factor in sound absorption Absorption is much greater in a relative humidity of ten to twenty percent As relative humidity rises toward or beyond 40 50 the absorption for all frequencies is considerably less The relative humidity factor is emphasized for higher frequencies High frequency absorption in low humidity can be several times greater than for low frequencies The bats at Carlsbad Caverns in New Mexico have to be closer to their flying prey to locate them as compared to more humid locations Please remember that we are explicitly referring to sound in air A PRACTICAL USE FOR ULTRASOUND There was little widespread commercial use of ultrasonic sound until the 1950 s and 1960 s when many televisions were equipped with ultrasonic receivers and external ultrasonic transmitters for remote control Devices using infrared light later replaced this type of remote control Research on devices using ultrasonic sound in air became relatively dormant after the loss of the only major product in that field Only a few engineers who were especially interested in the field continued to work with high frequency airborne sou
37. air because you do not have the right parts on hand Tires and Air Brakes Hear the leaks from a distance Simply scanning the vehicle will tell you if there is a leak in the air brake system or tires Once you hear the leak then you move closer and closer until you pinpoint the exact source When you do your walk around to check the lights you can detect tire or brake problems that would cause you trouble in today s run Railroads As the train rolls by you can hear the sounds of an airbrake leak but not the sounds of the train itself With the i Microsonic Detectors you can also hear a dragging brake as the train rolls by Once the train has stopped you use the detector to pinpoint the exact leak spot The Microsonic Detectors are good for finding leaks in the Diesel system around injectors and gaskets Using the stethoscope you can hear pistons moving individual valves opening and closing and listen to the flow at the injectors to hear clogged injectors Using the stethoscope to listen to the internal operation for correct sequencing facilitates trouble shooting pneumatic and hydraulic system problems 29 Bearings Over greasing a bearing is as bad as not greasing a bearing Too much grease results in too tight packing additional friction and pressure and heat build up By listening to the bearing with the Microsonic Stethoscope while adding grease you can determine the optimum 2n grease point Use the ste
38. als into recognizable audible signals where they are heard through headphones and seen as intensity increments on a meter A unique test incorporates a patented ultrasonic transmitter called a Wave Form Generator This device 1s placed in a cabin tank container or compartment where it floods the area with an intense ultrasonic signal The generated ultrasound will deflect off solid seals but will flow through a leak path Some of the most common areas for ultrasonic inspection include COMPRESSED AIR SYSTEMS CNG amp LNG GAS SYSTEMS VACUUM SYSTEMS INTAKE amp EXHAUST SYSTEM LEAKS ENGINE INTERNAL DIAGNOSTICS DRIVE LINE DIAGNOSTICS BEARINGS PUMPS MOTORS SERVOS AIR amp VACUUM ACTUATORS COMPARTMENT SEALS amp GASKETS HATCH BULKHEAD PORT WINDOW FLOOR amp ROOF SEALS HYDRAULICS FUEL INJECTORS DRIVE BELTS Detection Methods Pressurized air gas amp fluid leaks produce turbulence with high frequency components To locate air gas or fluid leaks under pressure simply scan the test area with the hand held EFI Microsonic detector If a leak is present ultrasonic sound not audible to the human ear is produced This high frequency sound will be heard by the EFI detector and converted into an audible hissing sound heard through the systems headphones Simply follow it to the loudest point If 1t is difficult to discriminate the leaks location reduce the sensitivity and continue to follow to the loudest point REMEMBER TO F
39. and translated via heterodyning down into the audible range The translated ultrasounds are heard through headphones and seen as intensity increments on a meter ufa uuud valve Leak Detection Method Inspection methods vary depending on the type of valve or steam trap Therefore the primary rule is to know the details of your system for example the way a specific trap or valve may work under specific conditions In order to determine leakage or blockage touch upstream of the valve or trap and reduce the sensitivity of the tool until the meter reads about 50 It is desirable to hear the specific sound quality of the fluid simply adjust the sensitivity until the sound you would expect to hear becomes clear It s that simple Next touch downstream of the valve or trap and compare intensity levels If the sound is louder down stream the fluid is passing through If the sound level is low the valve or trap is closed Ultrasonic valve and steam trap Inspection is considered a positive test in that an operator can instantly identify sound quality and intensity differentials and thereby determine operating condition accurately 48 The Microsonic Stethoscope has proven to be an extremely effective tool for testing steam traps for proper operation Thousands are now being used for this purpose and our customers have realized substantial savings in both maintenance costs and steam generation costs by using this method Energy costs wi
40. aulic systems Bypassing cylinders mal functioning valves and other system problems 33 ELECTRICAL Overhead Lines _ Hear the problem from the ground no need to climb 5 the pole or tower to tell where the leak is pk 3 Pressurization leaks in telephone overhead lines are readily heard from the ground Just walk the line aiming the detector at the lines until the leak is heard Switch Gear Pot Heads 3 Arcing Sparking Corona Leak detection Tracking Corona Tracking Corona Electrical Discharge Corona Arcing and Sparking in overhead power lines and transformers and other electrical equipment is readily detected Corona is heard as a 60 Hertz buzz arcing and sparking sound like crinkling cellophane sparking is intermittent arcing is continuous when heard using the Microsonic Detectors Electrical problems in switch gear and substations are easily spotted While you are checking the sub station don t forget to check air operated circuit breakers and for nitrogen leaks in the transformers Leaking insulators cause insulator deterioration and radio and TV interference These corona or arcing problems can be detected from the ground The higher the voltage the higher the line is above the ground but the higher the potential energy and thus the higher the ultrasonic energy that is created allowing you to detect the problem from the ground even for the high cross country lines Power Generatio
41. aulty steam traps bearings vacuum leaks and electrical problems before they cause serious disruptions is saving food companies thousands of dollars in unscheduled downtime Ultrasound detection tools provide information in two ways They let the operator hear ultrasounds qualitatively through a noise isolating headphone that blocks out plant noise and they display quantitative incremental readings on a meter The sensitivity of the tool can be adjusted to seek out particular sounds The detector can even record the sound of an eye blinking 36 Avoiding costly bearing failures Inland Empire Foods in Riverside CA pre cooks dehydrates and packages a wide variety of beans for resale to other food processing companies As part of Inland s preventative maintenance program it uses a lightweight ultrasonic detection system to make monthly inspections of bearings throughout the plant Ultrasound testing allows operators to hear sounds the human ear cannot detect under normal conditions All operating equipment and most leakage problems produce a broad range of sounds The high frequency ultrasonic components of these sounds have extremely short wave lengths and tend to be directional By pointing the ultrasonic tool in the direction of the object to be tested the signal is isolated from background plant noises and its location easily detected As subtle changes occur in mechanical equipment the directional nature of ultrasound permits potential
42. battery be sure to replace the battery with a fresh battery before sending your unit for repair The pistol unit uses a standard 9 volt battery located in the battery compartment on the left side of the pistol housing grip area The TG 2 Tone Generator uses four standard AA size batteries located under the battery compartment cover on the left side of the tone generator The tubular units use a standard 9 volt battery which is located under the battery cover toward the rear of the unit and Is accessed by removing the two slotted head screws If a fresh battery does not cure a failure carefully pack the kit and ship it to Service Department Phone 305 233 1640 Electronics For Industry Inc Fax 305 666 4185 6850 SW 79 Terrace oouth Miami Florida 33143 4440 Please include a short note describing your problem or troubles Your unit will be serviced promptly and returned to you If it is a warranty repair please include proof of purchase For your records record the date of your purchase For more information please visit our web site at http www e4i com Our e mail address iS efi e4i com service 9 edi com Sample Electronics For Industry a Inc CERTIFICATE OF CALIBRATION This certificate attests to the manufacturing standards and equipment calibration relating to the Electronics For Industry Inc line of Ultrasonic Detection equipment The equipment meets all existing standards as required It is ce
43. cation for marine vessels dry docks ship repair and shipbuilding Some of the major areas of inspection cover water tightness integrity of bulkheads leak detection of hatches and vapor recovery systems condensers steam systems pressurized gas systems including nitrogen blankets valve leak detection blockage and steam traps Mechanical applications include early warning of bearing failure inspection of motors pumps gears gearboxes and compressors Dry dock usage not only includes all of the above but also extremely large energy savings through compressed air leak detection How Ultrasonic Detection Works High frequency sounds are produced by operating equipment and fluid flows The Microsonic unit detects subtle changes in mechanical equipment and turbulence produced by leakage to provide early warning Ultrasounds are translated into the audible range where the sound quality 15 easily recognized through acoustically isolating headphones The headphones are designed to be used in the extremely noisy environment of the engine room Intensity levels are read on a meter for trending diagnosis and trouble shooting purposes A patented Tone Generator can be used to test for leaks in lieu of pressure by flooding an area with intense ultrasound The sound will deflect off a solid surface and penetrate leak sites Detection Methods To locate leaks around pressure or vacuum systems simply scan the area while listening for a hissing sound and fo
44. ces there are in some plants The savings is more than sufficient to cover and definitely justifies the cost of the repair staff the detection equipment all the tools a man lift and the materials needed to make the repairs Under these circumstances and with the costs involved in today s competitive market a leak detection program must be an imperative As the program progresses routine leak monitoring could and should be undertaken to assure that a high level of line leakage does not again become a source of loss to the plant Information furnished by the Institute For Nondestructive Testing Air leak costs based on 100 psig 0 22 Mcf and 867 hrs yr Nitrogen leak costs based on 150 psig 0 214 Ccf 8670 hrs hr industry standards for leakage and nominal area charges for Nitrogen cost Ccf often INCREASES with excessive consumption 76 PAY BACK ANALYSIS STEAM LEAKS In a steam system with 150 Ibs of pressure and a production cost of 6 per thousand pounds a leak 1 32 in diameter no larger than the tip of a ball point pen can cost 249 per year In a 50 p s i System with a production cost of 8 1000 pounds a number of small leaks totaling about 1 4 will cost 8 339 52 in one year Double the number of leaks to total 1 2 and the cost will be 33 358 08 At Sun Co s Toledo Ohio refinery the ultrasonic testing identified 188 malfunctioning steam traps Savings from replacing these traps have been in the range of 56
45. continuous flow 69 STEAM TRAPS THERMOSTATIC TRAP OPERATION C BASIC THERMOSTATIC TRAP OPERATION NORMAL LOAD NOTE Background noise level 0 CLOSED NO DISCHARGE 20 U i mm 100 SONIC DETECTOR MICH Indicator at 0 on scale shows valve is closed No steam leakage is indicated Bellows is expanded valve is closed on seat OPEN DISCHARGING CONDENSATE ee j 20 40 600 iMi The bellow is contracted the valve is open Indicator rises on the scale to show the trap is discharging condensate FAILED OPEN BLOWING LIVE STEAM MICROSONICIDETEC I OH Indicator pegs on scale accompanied by the high pitch sound Worn valve amp seat failed of steam passing through the open open bellows or bi metal etc valve seat 70 SECTION 9 STEAM COST CHARTS COST OF LOST STEAM STEAM FLOW THROUGH STEAM TRAP ORIFICE TABLE If you know the size of the discharge orifice in the steam trap you may use this table to estimate potential steam loss through a trap that has failed open Take the Ib hr figure X 24 hrs X 30 dys X 25 X 6 00 to establish the approximate dollar loss Diameter 47 2 12 1 16 1 86 8 5 3 32 4 20 19 1 1 8 15 34 0 5 32 117 53 1 3n 16 7 76 4 7 32 22 9 104 1 4 29 8 136 9 32 37 8 124 172 5 16 46 6 153 212 11 32 56 4 185 257 3 8 67 1 101 135 221 306 78 8 159 259 359 91 4 138 184 300 41
46. crease as you pass over the exact leak point In some loud factory environments shielding of the transducer may be required by using the rubber focusing extension or other shielding methods as explained below INTERFERENCE SOLUTIONS If there is ultrasonic interference in the vicinity of leak you are searching for reduce the sensitivity of the detector and work closer to the item being tested or try one of the following e 1 Turn your back to the source of interference so that the detector is facing away from the trouble source Ultrasound is extremely directional and your body acts as a sound block e 2 n extreme cases put an ultrasound blocker a sound barrier between the interference source and the area you are searching An ordinary clipboard placed to reflect the sound back in the direction of the interference works well A flexible curtain will absorb some of the sound and reflect some back toward the source of the noise Plastic sheeting is often used the smooth surface is especially effective in reflecting the sound back toward the source It is possible to make an 24 ultrasonic soundproof room or area in the midst of an otherwise noisy area this way 3 The rubber focusing extension is also helpful in screening out ultrasonic noise interference If there is too much ultrasound in the area reduce the sensitivity setting and continue to scan If it is difficult to isolate the leak due to competing ultrasound place the
47. d noise level 0 Rie ve Indicator at 0 on scale shows valve SS closed and no steam leakage Bucket up 1 o 100 e 4 gt S nam 11 m MICROSONIC bETECTOR n I ots o m ro J Indicator rises on scale to Bucket down valve open show trap is discharging 3 FAILED OPEN BLOWING LIVE STEAM BO niu 100 Wi MICROSONIC DE ILIA TOR Bil J Indicator Pegs on scale along B ecket linkade d puck with high pitched sound of steam ucket linkage damaged bucket Badly worn valve amp seat passing through open valve seat 59 STEAM TRAPS INVERTED BUCKET TRAP E NOTE Background noise level 0 4 LOSS OF PRIME Badly worn linkage prevents valve from seating properly or loss of prime as a result of over sizing registers Erratic and rapid back amp forth movement of indicator accompanied by an audible metallic ringing noise caused by the bucket dancing inside the trap body 5 LEAKING STEAM As a result of wear the valve will not seal properly allowing steam to leak through the seat Indicator needle does not return to 0 or level of ambient noise between cycles indicates leakage 60 gt STEAM TRAPS THERMODYNAMIC TRAP A Place probe on trap as shown Thermodynamic disk traps can opera
48. densate entering the trap causes the float ball to rise and lifts the valve through leverage off the seat thus discharging condensate continuously at steam temperature 65 STEAM TRAPS FLOAT amp TRAP OPERATION B BASIC F amp T TRAP OPERATION NORMAL LOAD NOTE Background Noise Level 0 A CONDENSATE VALVE Continuous modulating discharge No on off cycle 5831 1 ra 1 T L M Indicator moves back amp forth smoothly indicating the modulating effect of the Float moves up and down float amp valve continuously discharging continuously condensate B AIR VENT uw I 1 Note indicator reading 2 Take reading on pipe upstream of trap or bypass air vent At pre set temperature below 3 Normal if reading 2 is greater than 212 F thermostatic element reading 1 closes air vent valve on seat 4 Air vent is leaking if reading 2 is less than reading 1 FAILED OPEN BLOWING LIVE STEAM MUI MICROSONMIC DETR Indicator pegs on scale accompanied Worn valve amp seat broken by high pitch sound of steam passing linkage damaged float etc through open valve seat 66 STEAM TRAPS FLOAT amp TRAP OPERATION C DETAILED F amp T TRAP OPERATION The Float amp Trap discharges condensate continuously without any distinct on off cycle 1 LIGHT LOAD Continuous discharge of condensate under light load conditions will regi
49. e technician can cup a hand over the end of the probe to scan close to the surface of the test area After the equipment has been repaired the tag is removed but the recording sheet should be kept for reference Finally the technician should monitor the load of the air compressors are too large for its real air demands Many compressors are designed to operate most efficiently at or near full load Ifa 81 compressor is consuming 80 percent of the input power to deliver 50 percent of its capacity following repairs the plant might be wise to consider smaller air compressors The savings can be substantial After the number of air leaks has been determined and repairs have been made it is important to document the program including an estimate of projected cost savings The costs of labor materials cooling water and other related expenses must be factored in AIR LEAK COST CHARTS Information provided by The Institute For Nondestructive Testing 1999 Leak Diameter in inches 1 64 1 32 3 64 1 16 3 32 1 8 3 16 1 4 5 16 3 8 Air Loss 0 5 1 6 3 7 6 5 14 5 25 8 58 3 103 0 162 0 234 0 Air Loss cu ft day 576 2 304 5 270 9 288 20 880 37 152 83 952 148 320 233 280 336 960 Loss per Day 0 14 0 58 1 32 2 32 5 22 9 29 21 00 37 08 58 32 84 24 Note Based on 100 psig 0 25 Mcf 8760 hours year Loss per Month 4 20 17 60 40 10 70 50 158 70 282 40
50. e to that of the leak detectors The transformer structures can vibrate at the operating frequency and generate ultrasonic noise A noisy high voltage flyback transformer is an example This noise when heard using a leak detector does not sound like a leak it usually sounds more like a tone buzz or whistle This is a good example of where the meter reading would only tell part of the story The meter would read as if a leak were being detected but by listening you would be able to identify the type of sound and know it was not a leak Arcing Electrical arcing creates turbulence in the air which creates ultrasound Again the signature is different from that of a leak Low level arcing called corona would sound like a 60 cycle buzz Arcing or sparking as around a defective spark plug wire would sound more like crinkling cellophane 26 ADVANCED METHODS OF FINDING STUBBORN OR HARD LEAKS WAVE GUIDES When a suspected leak source has been identified by scanning an area that is not easily accessible for leak verification a simple wave guide can be used to gain access to an ultrasonic emission A simple wave guide can be made from 3 4 inch PVC tubing cut to the desired length One open end is extended to the suspected area and the leak detection unit W7 or El 500 is inserted in the other end Ultrasonic emission if present will travel within the tube to the detector A flexible wave guide can be made from 1 75
51. eater pressure differential causes increased turbulent energy For practical purposes pressure differentials of 5 psi are at the lower limit of delectability but with small holes in rigid material leaks with a pressure as small as one half pound pressure have been successfully detected Higher pressures can cause the acoustic waves to have a higher and more constant amplitude making leak testing easier and more reliable There has been considerable discussion as to which type of leak configuration is more likely to cause acoustic vibrations Several authors have held that labyrinth type leaks such as threaded fittings or folded metal edges would diffuse the turbulent vibrations to such an extent that turbulent flow would be undetectable Actual tests however have proven that even with pressure differentials as low as 10 psi labyrinth leaks can be detected Liquid Movement Besides turbulent flow liquid movements such as cavitation flashing of a liquid to a vapor and bubble bursts can also produce high energy ultrasonic noise Cavitation can be especially useful for finding small vacuum leaks which are usually considered difficult to find ultrasonically By applying a high surface tension liquid such as alcohol on the area to be tested the ultrasonic energy produced as the film is broken by the vacuum creates a signal which is detectable at a distance of several feet In the same way small bubbles from synthetic bubble fluids applied acro
52. ecially beneficial in areas where there is a saturation of gases or where a wide variety of gasses pressurized vessels and vacuum processes exist 22 Time and convenience are also improved with ultrasonic detection since equipment may be tested and leaks located while on line and all the machinery is still operating It can be generally noted that the larger the leak the greater the ultrasound level GENERAL LEAK DETECTION METHOD Ultrasound is a high frequency short wave signal The intensity of the ultrasound produced by a leak drops off rapidly as you move away from its source For this reason the leak sound will be loudest at the leak site Ultrasound is fairly directional and therefore pinpointing the source i e the location of the leak is quite simple Using the leak detector with the sensitivity set at maximum scan the general area of a suspected leak by waving the detector back and forth and listening for an increase in the hissing sound similar to the sound you hear when you fill a tire with air in the headset and or a peaking of the meter reading Move in the direction of the loudest sound If it is hard to determine the direction of the loudest sound reduce the sensitivity until direction can be established Follow the sound and continue to reduce the sensitivity to determine the direction of the leak In order to confirm the leak site move the detector back and forth over the suspect area The sound level will in
53. ecific valve may work under specific conditions In order to determine leakage or blockage touch upstream of the valve and reduce the sensitivity of the instrument until the meter reads about 50 If it is desirable to hear the specific sound quality of the fluid simply adjust sensitivity until the sound you would expect to hear becomes clear It s that simple Next touch downstream of the valve trap and compare intensity levels If the sound is louder down stream the fluid is passing through If the sound level is low the valve is closed Ultrasonic valve inspection is considered a positive test in that an operator can instantly identify sound quality and intensity differentials and thereby determine operating condition accurately Example of a leaking valve MICROSOMC DETECTOR 50 SECTION 8 STEAM TRAP TESTING AND ANALYSIS Steam Traps and Valves Explained How to analyze them using the Ultrasonic Tools Determine good and bad traps and predict failure This section prepared by Mr Alex Allison Of Allison Mechanical Inc Des Moines lowa Our thanks to Mr Allison And more thanks to Mr Doug McMordie Who created the trap diagrams Steam Traps Where are they 51 STEAM TRAPS PREFACE Any method used to check the operating performance of steam traps requires experience on the part of the individual conducting the test The reason is that a great number of variables exist causing many different i
54. elate to the size and consistency of the male eardrum as compared to the female The older one gets the more high frequency hearing loss is present Even though we humans don t have much sensitivity to the higher or to us ultrasonic frequencies these sounds exist in nature Bats use high frequency sonar to zero in on flying insects at and after dusk Crickets rub their legs together and generate considerable high frequency noise as part of the chirp that we hear lt is interesting to listen to crickets or bats with an EFI leak detector Some species of fish use very low frequencies for communication of a sort and others use high frequencies Rodents can communicate at frequencies far above our hearing range up to 100 000 Hertz Dogs and cats have high frequency hearing sensitivity above our limits The so called silent dog whistles generate high frequency sound that dogs can hear but humans cannot As the frequency or pitch of sound rises toward and beyond our upper hearing limit its characteristics change considerably If the source is directional such as inside a room with an opening the low frequencies tend to spread out from the opening source of sound High pitch sounds tend to form more of a beam and the effect is more pronounced as the pitch rises Higher frequencies are more directional We know that if a sound source is distant it does not sound as loud the intensity is lower Sound is absorbed as it passes through
55. electric utility potheads bushings and arresters in substations were scanned Fig 1 This utility was experiencing arrester failures that caused troublesome power interruptions The ultrasonic detector indicated tracking on several of the arresters Further investigation isolated ultrasound coming from an area of intense corona and arcing On inspection the connection was found to be pitted and corroded Fortunately the 138 kV equipment was only operating at 12 load at the 42 time Had it been operating at full load the connections would probably have disintegrated interrupting power to 80 000 to 100 000 customers Interlocked metal enclosed switchgear serving a large shopping mall was examined with an ultrasonic detector Ultrasound was detected in a very localized area Closer examination suggested arcing and tracing was occurring within the switch Utility and mall maintenance personnel were called to deenergize the system and open the switch to perform a visual inspection They found corona and tracking had destroyed 35 of the switchblade and that the contact surface was close to failure Transformer voltage taps that run hot cannot be detected with infrared equipment because the heat from the transformer barrel is greater than that from the loose connection During inspection of a 1500 dry transformer Fig 3 serious tracking and arcing was heard in the secondary voltage tap When the connections were dismantled carbon bu
56. ensity increments on a meter Leak Detection Method Most often leak detection is concerned with tube leaks In heat exchangers and condensers there are situation where the end plates headers are removed or water boxes are isolated while the unit is still on line or at partial load The tube sheet is scanned while listening for a distinct hissing or rushing sound of a leak By adjusting the sensitivity of the instrument to help discriminate direction move in the direction of the tube with the loudest sound Should the unit require off line inspection it is possible to use the Ultrasonic Tone transmission method Using ultrasonic transmitters such as the patented Tone Generators the heat exchanger is flooded with intense ultrasonic sound waves on the shell side and the tube sheet is scanned for a distinct tone sound coming from the leak As above adjust the sensitivity to discriminate direction and follow the sound to the loudest point which will be the leaking tube While under pressure or vacuum fittings and casings may also be checked for leakage in a similar manner REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 99 ELECTRICAL ULTRASONIC INSPECTION DESCRIPTION When electrical apparatus such as switch gear transformer insulators or pot heads and splices fail the results can be catastrophic This is just as true in industrial plants as it 1s in the power transmission and distribution side Electrical discharges s
57. esult in internal damage to the Stethoscope Module Sensitivity adjustments and calibration are essentially the same as described above for Leak Detector use with the following added stethoscope only adjustments If when using your stethoscope you find the unit is too sensitive the meter remains at full scale when the volume sensitivity knob is all the way down reduce the sensitivity of the Stethoscope Module itself by adjusting the potentiometer located in the module Use the screwdriver supplied with your kit to turn down the control through the hole on the side of the module until the meter remains on scale The Microsonic Stethoscope will detect internal sounds in the ultrasonic range It does not detect the sounds that the ear can hear or other low frequency sounds such as a heartbeat The friction between moving parts of machinery generates ultrasonic sound As a general rule the ultrasonic sound is very similar to the low frequency sound heard by your ears a mirror image but displaced in frequency If you touch the probe to the case of a mechanical watch for example the ticking sound is similar to that heard with the unaided ear The sound from the stethoscope however has much better definition Minute sounds are present that was not noticed before 39 The stethoscope is detecting sound generated by the friction of the parts rubbing together and not just the clicking sounds of the escapement or gear wheels meshing As
58. et shown with tubular detectors is designed to be worn with the tubular band under the chin this allows for the wearing of a hard hat if necessary Firmly placing the ear elements in the ear will also provide for reduction of outside noises It is highly recommended that you use the headset when using your detector Listening as well as keeping your eyes on the meter as much as is safe makes a search easier The additional information you get frequency repetition rate and sound discrimination makes locating and pinpointing problem areas much quicker The meter displays only the sum of all the sounds However use of the headset is not absolutely necessary the headset does not even have to be plugged in for operation of the pistol style detector PISTOL STYLE DETECTORS Model EI 701 is the pistol body only Meter o Tum detector ON by depressing Tigger Headset Receptacle L 1 LEAK DETECTOR MODULE L__ Module Sensitivity Adjust Use small sortewdiiver supplied Module Sensitivity Adjust SM 1 STETHOSCOPE MODULE MODEL El 701 DETECTOR BODY LM 1 LEAK DETECTOR MODULE MODULES PLUG INTO THE FRONT OF THE DETECTOR BODY TO MAKE EITHER MODEL El 701L LEAK DETECTOR OR A MODEL El 701S STETHOSCOPE 12 TUBULAR STYLE DETECTORS EI 500 Leak Detector Leak detection Aluminum ae _ module Single adjustment for on off sensitivity volume EI
59. expensive easy to use and highly portable 87 SECTION 11 FEATURES AND PRICE COMPARISON OF COMPETITIVE EQUIPMENT gt EFI W 7 Microsonic Detection Kit gt UE Systems Ultraprobe 2000 Detection Kit gt SDT USA 150 Detection Kit EFI Electronics for Industry UE Systems SDT USA W 7 Industrial Detection Kit Ultraprobe 2000 Detection Kit SDT 150 Ultrasonic Detection Kit analog amp audio indication analog amp audio indication audio indication Inexpensive 9V batteries and AA Rechargeable batteries amp Rechargeable batteries amp batteries You can t use a charger charger charger in the field ni cads memory degradation ni cads memory degradation Tool Case Case Warranty 1 Year Parts Labor Warranty 1 Year Parts Labor Manufactured USA Manufactured USA Manufactured Europe 88 SECTION 12 SPECIFIC USES AND APPLICATIONS This section contains separate printable pages for many of the more common problems that can be solved with the Electronics For Industry Inc tools You may wish to print these pages and use them as justification for buying and using Ultrasonic Tools in your plant shop hospital or other applications INDUSTRIAL amp COMMERCIAL ULTRASONIC INSPECTION DESCRIPTION Inspection of mechanical equipment with EFI ultrasonic detection equipment has many advantages Ultrasound inspection provides early warning of bearing failure detects lack of lubrication detec
60. gnals into recognizable audible signals where they are heard through headphones and seen as intensity increments on a meter A unique test incorporates a patented ultrasonic transmitter called a Tone Generator This device is placed in a cabin tank or container where it floods the area with an intense ultrasonic signal The generated ultrasound will deflect off solid seals but will flow through a leak path Detection Methods Pressurized air amp gas leaks produce turbulence with high frequency components To locate compressed air and gas leaks simply scan the test area with the hand held EFI Microsonic detector If a leak is present ultrasonic sound not audible to the human ear is produced This high frequency sound will be heard by the EFI detector and converted into an audible hissing sound heard through the systems headphones Simply follow it to the loudest point If it 1s difficult to discriminate the leaks location reduce the sensitivity and continue to follow to the loudest point REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 90 BEARINGS PUMPS amp MOTORS ULTRASONIC INSPECTION DESCRIPTION Inspection of mechanical equipment with ultrasonic instruments such as the Microsonic unit has many advantages Ultrasound inspection provides Early warning of Bearing failure Early warning of Poor of lubrication Prevent over lubrication during maintenance Effective on High amp Low speed bearings Detect carbon brush Ho
61. he two technologies complement each other and enhance any Predictive Maintenance program Some common areas for ultrasonic inspection in the amusement ride industry include e COMPRESSED AIR SYSTEMS FOR LEAKS AIR BRAKE SYSTEMS FOR LEAKS VACUUM SYSTEMS FOR LEAKS BEARINGS FOR EARLY WEAR ELECTRIC MOTORS FOR BEARING WEAR BRUSH HOP AND ELECTRICAL SHORTING ELECTRIC PANELS FOR ARCING AND SHORTING DRIVE BELTS FOR CRACKS AND WEAR with equipment in operation amp belt guards in place PUMPS FOR INTERNAL WEAR amp LEAKAGE HYDRAULIC SYSTEMS FOR INTERNAL LEAKAGE RAILS TRACKS amp SUPPORTS FOR LOOSE COMPONENTS amp LEAKAGE FILTRATION SYSTEMS FOR FLOW How Ultrasonic Detection Works Compressed gases when leaking produce a turbulent flow with strong ultrasonic components By scanning fittings a leak will be heard as a distinct hiss Due to the high frequency short wave nature of ultrasound the sound will be loudest at its point of origin The Microsonic unit translates the ultrasonic leak signals into recognizable audible signals where they are heard through headphones and seen as intensity increments on a meter A unique test incorporates a patented ultrasonic transmitter called a Tone Generator This device is placed in a cabin tank or container where it floods the area with an intense ultrasonic signal The generated ultrasound will deflect off solid seals but will flow through a leak path Detection Methods Pressurized ai
62. hod for detecting incipient bearing failure The ultrasonic warning appears prior to a rise in temperature or an increase in driving torque Ultrasonic inspection of bearings is useful in recognizing the beginning of fatigue failure brinelling of bearing surfaces flooding of or lack or lubricant In ball bearings as the metal in the raceway roller or bearing balls begins to fatigue a subtle deformation begins to occur This deforming of the metal will produce an increase in the emission of ultrasonic sound waves When testing changes in amplitude of from 12 to 50 times the original reading is indication of incipient bearing failure When a reading exceeds any previous reading by 12 dB it can be assumed that the bearing has entered the beginning of the failure mode This information was originally discovered through experimentation performed by NASA on ball bearings In tests performed while monitoring bearings at frequencies ranging from 24 through 50 kHz the changes in amplitude indicated the onset of or incipient bearing failure before other indicators including heat and vibration changes An ultrasonic system based on detection and analysis of modulations of bearing resonance frequencies can provide subtle detection 35 capability whereas conventional methods have difficulty detecting very slight faults As a ball passes over a pit or fault in the race surface it produces an impact A structural resonance of one of the bearing comp
63. hould Are the seals leaking Hear the problem in its early stages so there is time to plan repairs don t wait for disaster to strike 30 Diesel or Gas engines Listen to pistons valves vacuum systems head gasket leaks Find faulty injection systems irregular firing as well as carburetor and intake leaks All these problems and more are easy to find using the Microsonic Detectors because you do not hear the background noise or the other noises that your normal ear hears and that keep you from hearing and finding these problems with your unassisted ears Steam Traps Is it stuck open is it stuck closed Does it cycle properly Is my steam trap working as it should t 1 Listen with the Microsonic Stethoscope and you will LA T answer all these question with the greatest of ease Even with the plant noises at their highest level you can hear the operation of your steam trap because the Microsonic detectors do not hear all that other plant noise Wind Noise and Water Leaks in Vehicles Put the Tone Generator inside the vehicle and turn it on It fills the compartment with high intensity high frequency sound energy Sound will not pass through a solid but it will find any opening and work its way through A leak is an opening from the outside to the inside Anywhere there is an opening the high frequency energy will escape Using the Microsonic Detector you will hear the escaping energy as a tone or whistle in the
64. ildup and arcing traces were found in the tap contacts In each of these cases problems were detected that could not have been found without de energizing the equipment In some cases even a visual inspection would not have found the defects Ceramic Stres Tracking Corona _ Switch Gear Pot Heads Corona Leak detection Arcing Sparking Tracking Corona DESCRIPTION When electrical apparatus such as switchgear transformer insulators or potheads and splices fail the results can be catastrophic This is just as true in industrial plants as it is in the power transmission and distribution side Electrical discharges such as arcing tracking or coronas are all potential for equipment failure In addition the problems of RFI and TVI impact on our valuable communication networks All these conditions produce ultrasound and are detected with the Ultrasonic detection unit 43 How Ultrasonic Electrical Detection Works Arcing tracking and corona all produce some form of ionization which disturbs the air molecules around it The Ultrasonic unit detects the high frequency noise produced by this effect and translates it via heterodyning down into the audible ranges The specific sound quality of each type of emission is heard in headphones while the intensity of the signal is observed on a meter Normally electrical equipment should be silent although some may produce a constant 60cycle hum or s
65. inch rubber hose or the rubber focusing extension can be used Ultrasonic emission travels through tube to detector LIQUID LEAK AMPLIFICATION Liquid leak amplification is the use of a LOW surface tension fluid that produces a thin film through which the escaping gas will pass When it comes in contact with a low flow of gas it quickly forms a large number of small bubbles that burst as soon as they form This bursting effect produces an ultrasonic shock wave that is heard as a crackling sound in the headphones In many instances the bubbles will not be seen but they will be heard This method is capable of obtaining successful leak checks in systems with leaks as low as 106 standard cc sec If there are situations where a signal may be difficult to isolate it may be helpful to reduce sensitivity Point the system toward the test area and gradually reduce sensitivity until the weak signal becomes clearer and then follow basic detection methods When testing for low volume pressure leaks apply liquid at the test area and scan With the leak detector For valve stems seams flexible materials and seals the contact probe can be used at the suspected leak point 27 SECTION 4 USES amp APPLICATIONS USES FOR THE TOOLS Typical Applications e Pinpoint pressure and vacuum leaks of any gas air steam or vapor e Find leaks around seals seams welds hatches fittings and bulkheads without pressure Listen to internal mechanica
66. ion before serious damage occurs Find and fix those pesky wind noise whistles Using the stethoscope you can listen at the face of the gyro instruments to tell which one is starting to have trouble don t wait until it fails in flight predict failure and fix it before it becomes critical Seams and Seals Find leaks around doors chambers around windows in roofs refrigerators or compartments virtually any enclosed area Find leaks in soundproof rooms Find where you are losing air conditioning and heating Seal your premise why pay to heat or air condition the great outdoors Place the Tone Generator on one side of the surface to be tested or inside the enclosure and work the outside to listen for the Tone that indicates a leak Repair it seal it and then re check it to be sure it was done properly Delicate Machinery The extreme magnification of internal sound by the Microsonic Stethoscope allows you to hear the changes in even the most delicate bearings or machinery If you know what you are listening to you can even hear the mechanism of a fine safe or lock By listening over a period of time you will develop a sound pattern that is normal for you machinery When something starts to go bad you will know it and be able to effect repairs before the machine is damaged or the precision work it is supposed to do is compromised Hydraulics Using the Microsonic Stethoscope you will readily hear malfunctioning hydr
67. ir than is normal noise The detectors listen for noise in the 40 kilohertz region This is a compromise Lower frequencies are more susceptible to common low frequency noises Higher frequencies are absorbed to a greater extent as they pass through the air To better visualize leaks consider a hose attached to a bib or faucet The water is turned on and there is a shutoff nozzle on the end of the hose You might find a damp spot somewhere along the hose where a leak will soon be apparent There might be another spot with a very small hole that gradually forms a drip Surface tension of water tends to hold it together until there is sufficient mass to pull it loose as a drop There might also be a small hole in the hose that squirts a very fine stream of water Finally there might be a leak in the valve with water coming out around the turn off valve stem If the water pressure were quite low all of these problems would be less apparent When the pressure is increased each would be emphasized and become more prominent Suppose now that the same system is drained and dry and is pressurized with air The spot that was damp might or might not generate ultrasonic noise Increasing pressure would increase the likelihood of detection The source of the drip would probably be easy to detect The air does not have surface tension and there would be a small steady leak from the hole As the air escapes from the holes there would be turbulence and no
68. ise generated As the pressure increases noise increases The hole that had a very fine stream of water should generate lots of noise and be detectable at a considerable distance 21 Remember that this noise is generated at the point where gas is liberated from the higher pressure area inside the hose through the hole and out into the lower pressure area As the higher pressure leakage passes into lower pressure outside turbulence results which creates the noise In the case of the faucet or any valve and sometimes with threaded fittings a different condition can exist The high to low pressure transition can occur inside the structure at the valve seat itself This is the point of maximum energy and maximum sound generation The sound then must travel through the air path following the threads or down the hose to the exit point losing energy as it travels An example of this would be a welding tank where the valve has not closed completely The leak is actually at the valve seat this is the point of maximum energy The sound now travels down the hose losing energy as it travels to the welding tip which is a much larger opening and also disburses the energy instead of concentrating it as a smaller hole would The result is often less noise than would be expected requiring the detector to be closer to the leak Folded or rolled metal seams joints on containers or high quality ductwork can cause similar problems A cross section of
69. isten for the loudest hissing sound and follow the sound to the loudest point Use the patented Tone Generator to test for cabin pressure and cockpit window leaks 1n the same manner The only difference will be the sound which is heard as a distinctive tone with graduating intensity For valves and actuators touch upstream and reduce the sensitivity to a mid line reading Compare with the downstream reading Test bearings and mechanical equipment by reducing the sensitivity first and then tune the frequency until the desired mechanical sound is heard Compare readings over time for trending It s that simple 977 REMEMBER FIX IT FIRST YOU HAVE TO FIND AMUSEMENT RIDE INDUSTRY ULTRASONIC INSPECTION 2 4 i NN te uz UR AS WAS 7992 64 Inspection of mechanical equipment with EFI ultrasonic detection equipment has many advantages Ultrasound inspection provides early warning of bearing failure detects lack of lubrication detects leaks in compressed air and vacuum systems prevents over lubrication and can be used on high as well as low speed bearings In addition since ultrasound is a high frequency short wave signal it is possible to filter out stray confusing background noises and focuses on the specific item to be inspected Basic inspection methods are extremely simple and require very little training In addition ultrasonic testing works extremely well with vibration technology In fact t
70. ity You do not hear people talking or machinery running ULTRASONIC LEAK DETECTION Pressure amp Vacuum Leaks Leaks generates noise Sometimes we can hear it with our ears sometimes not Whether we can hear it or not depends on many factors such as 1 The amount of other noise in the vicinity to mask it 2 The size of the leak 3 The characteristics size and shape of the hole that allows the leakage 4 The type of material and its thickness 5 The pressure or vacuum that forces the gas in or out of the hole Leaks generate turbulence which generates ultrasonic noise as well as noise that we can hear with our ears The problem with listening for leaks with our unaided ears is that our ears are not sensitive enough nor directional enough especially for small leaks Another problem is that there is almost always some noise in the vicinity to mask the leak source sound Turbulence is produced as fluid or gas moves from high to low or low to high pressure This turbulence contains strong ultrasonic energy that is detectable by the EFI detection units This ultrasonic emission once detected is heterodyned shifted in frequency into the audible range where it can be heard by the human ear through earphones or viewed as an analog readout on a meter C Adres phar re Sensing ultrasounds generated by a leak the Microsonic unit can be used to locate leaks in pressurized systems regardless of the type of gas used This is esp
71. l operations to predict failure or track wear Compressed air leaks Steam systems Traps Valves Gaskets Boilers Check bearings for wear and lack of lubrication Motors Pumps Gear Boxes for internal wear Electrical Systems for Arcing Sparking and Corona Hydraulic Systems Valves Seals Controls Drive Belts for cracks wear and slippage Enclosed Areas Rooms Containers Roofs Windows etc Check Valves Gaskets Seals and Seam Leaks Identify and locate engine transmission or rear end noises The Microsonic Stethoscope allows you to hear the noises from inside machinery without hearing all that is going on around you By contacting the housing in the vicinity of the moving parts you will hear what is happening inside Is it a smooth normal sound or a rough intermittent or grinding sound To listen to rear ends differentials rear axles with the vehicle on a lift you listen at various points while turning the wheels by hand to control the speed and better identify problems Engines are analyzed by listening to the individual valves and pistons Since ultrasound does not travel as normal sound does you can actually hear individual valves Bad spark plugs leaking transmissions radiator or block leaks are best found with the Microsonic Leak Detector Pinpoint Pressure or Vacuum Leaks The Microsonic Leak Detector hears the high frequency energy created by any gas or vapor escaping in or out of an orifice The
72. l to the pipe until finding the leak Then the instrument s close focus adapter can be honed in on the exact location of the leak The problem may actually be in the fitting When testing for leaks in air or blow off applications near open air tubes for example the technicians must focus the tool away from interfering noise and isolate the ultrasonic sounds Every leak should be tagged with the location and an identification number A note should also record a description of each leak including the size The make and serial number of equipment such as quick couplers filters regulators and lubricators that may be causing a chronic leakage problem should be recorded so as to avoid purchasing the part again The technician should double check each leak that is repaired before moving on to the next area Often new leaks are inadvertently created during the repair stage and go unnoticed because the part is not retested Using confirmation and shielding techniques such as sealing always pays off when the entire connection is checked one final time Confirmation techniques include moving the ultrasonic detector back and forth over the leak site to confirm the loudest point The technician places the rubber focusing extension over the suspect area to seal it from the environment If this area is the sources of the leak the sound will continue If not it will diminish For the shielding technique the rubber focusing extension is used alone or th
73. leak 1s found Ordinary sounds such as background noise talking or machinery no matter how loud are not detected But leaks are easily pinpointed even in otherwise deafening background sound levels REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 02 STEAM TRAP VALVE amp FITTINGS ULTRASONIC INSPECTION Hn os aP T E B P 7 When valves or steam traps leak or fail it can be extremely costly in terms of product quality safety and energy loss Valve operation affects the way fluids will flow through a system There are great differences in the way particular valves and steam traps work Ultrasonic testing makes it easy to adjust for these differences and readily determine operating conditions while valves and traps are on line i L DESCRIPTION How Ultrasonic Leak Detection works As fluid moves from the high pressure side of a valve through the seat to the low pressure side it produces turbulence This turbulence generates ultrasound which 1s detected by the ultrasonic probe and translated via heterodyning down into the audible range The translated ultrasounds are heard through headphones and seen as intensity increments on a meter High frequency tuning allows users to adjust for differences in fluid viscosity i e water vs steam and reduce any interference from stray pipe noises d N 1 s s gt A C D TEST FOINT B TEST POINT C EE REN
74. ll certainly continue to escalate and an effective energy conservation program can make the difference between profit and loss The passage of steam through an aperture generates ultrasound as does the friction between the operating components of a steam trap With the EFI tool we can hear these sounds and by interpreting what we hear we can determine if a steam trap is operating normally There are several types of steam traps on the market but all have the same purpose that is to remove condensed steam air and gasses from the system and thereby improve efficiency and protect the system from damage Steam pressure temperature and capacities determine what type of trap will be used in a particular application A steam trap that fails in the open position will discharge live steam thereby wasting energy and degrading system performance A steam trap that fails in the closed position will not discharge condensate and damage may result to system components There are two main types of steam traps those that discharge condensate intermittently and those that discharge continuously In the first category are the inverted bucket design and the disk thermodynamic design Float thermostatic and float thermostatic designs comprise the second category Testing methods are essentially the same for both types and we assume that the proper type trap has been selected for the particular application The first step in testing a steam trap is to de
75. llow it to the loudest point Vapor recovery systems can be checked on line in this manner Hatches and bulkheads may be tested with the patented ultrasonic Tone Generator Place the generator on one side 1 of the bulkhead and scan the other side for sonic penetration which will have a distinctive tone sound Scan the area to the loudest point of emission which will indicate the leak site For valves touch upstream and reduce the sensitivity to get a mid line reading on the meter then touch downstream and compare intensity levels A more intense reading downstream indicates leakage No sound indicates blockage Set a baseline by selecting one test reference point touch that point with the contact probe and reduce the sensitivity to obtain a mid meter reading An increase of 8 dB indicates pre failure or lack of lubrication while an increase of 12 16 dB over baseline indicates the beginning of the failure mode It s that simple REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 96 AIRCRAFT ULTRASONIC INSPECTIONS DESCRIPTION Aircraft have many systems that can be checked ultrasonically Some of the more common applications include Locate leaks in oxygen systems Locate cabin pressure leaks Locate tire leaks Locate problems in hydraulic valves and actuators Locate leaks in cockpit windows amp doors Locate problems with bearings pumps motors and gears Locate leaks in floatation devices Locate leaks in fuel cells
76. n Power generating stations have most of the problems that are found elsewhere in this document Pinpoint Vacuum leaks RE pressure leaks pneumatic controls bearings controls hydraulics compressors switch gear malfunction pumps electrical corona arcing and sparking All these problem areas and more are areas of use for the Microsonic Detectors 34 SECTION 5 MECHANICAL ULTRASONICS Mechanical Ultrasonics ROTATIONAL EQUIPMENT PRODUCES AN ULTRASONIC EMMISION RESULTING FROM FRICTION BETWEEN MOVING PARTS How Mechanical Inspection Works Mechanical movements produce a wide spectrum of sound By focusing ona narrow band of high frequencies the Ultrasonic unit detects subtle changes in amplitude and sound quality It then heterodynes these normally undetectable sounds down into the audible range where they are observed on a meter for trending and comparison purposes and heard through headphones Based on research by NASA it was established that ultrasonic monitoring provides early warning of bearing failure Various stages of bearing failure have been established An 8 dB gain over baseline indicates pre failure or lack of lubrication A 12 dB increase establishes the very beginning of the failure mode A 16 dB gain indicates advanced failure condition while a 35 50 dB gain warns of catastrophic failure Mechanical Ultrasonic Detection Mechanical inspection Ultrasonic inspection and monitoring of bearings is a reliable met
77. n the signature of a component and pinpoints potential source of failure before they cause costly damage The longer wavelengths of lower pitched sounds travel easily and can be heard without special equipment Higher frequency sounds cannot penetrate solids yet they slip through the tiniest of openings Ultrasound detectors are ideal for isolating such leaks These lightweight tools are battery powered so operators can easily move from machine to machine Their circuitry translates the high pitched ultrasounds to those in the human hearing range enabling users to hear a mirror image of the ultrasounds through headphones and gauge their intensity by the increase in sound in the headset and increasing reading on an analog meter Any ultrasonic tool should be checked for an intrinsically safe rating before it is used in hazardous areas ULTRASOUND AND LEAKS EFI started production of its line of leak detector tools in the early 1960 s Then as even now the only generally practical alternative to these tools for locating leaks is the slow inconvenient painting of suspected leak areas with soapy water then watching for bubbles to appear The EFI detectors are extremely sensitive to the ultrasonic noise generated by leaking pressurized air or other gas including steam but they are as insensitive to ordinary noise as our ears are to ultrasonic noises The detectors convert ultrasonic sound waves down to sounds that we can hear with our ears
78. nd Few other commercial applications have surfaced since the remote control era Of course if you see a bat flying toward you you can frighten it away by giving it a blast of ultrasonic sound but one does not see a bat flying toward one very often Production of an ultrasonic Bat Chaser doesn t seem practical A very loud source of high frequency sound energy can frighten mean dogs away This is another practical application HOW AIRBORNE ULTRASOUND TOOL TECHNOLOGY WORKS Ultrasounds by definition are beyond the limits of normal human hearing so an inspector uses a sophisticated tool to translate ultrasonic signals to the range of human hearing The theory of ultrasonic detection is relatively simple Frequency the number of times a sound wave cycles from trough to crest is expressed in cycles per second and measured in hertz One kilohertz is 1000 cycles per second The best human ears can generally hear noises in the range of 20 to about 20 000 Hz 20kHz Ultrasonic detectors work at approximately 40 kHz far above human hearing range Thus mechanics using the ultrasound tool can hear what is going on in operating machinery Fluid and gas systems and other working machinery have constant ultrasound patterns When a leak occurs the fluid passing through produces turbulence with strong ultrasonic components Changes in the sonic signatures can be readily recognized as wear in components An ultrasonic detector senses subtle shifts i
79. nd which will leak through any openings Scan the surface seams and seals with the detector using the leak detector module Anywhere there is a leak the tone will be heard As stated before the leak source is the loudest point and as you approach the source you may need to reduce sensitivity in order to pinpoint the exact spot Do not point the detector directly at the tone generator as the energy is so intense it my block the detector it will not harm the detector but you will not hear any tone To test the Tone Generator turn it on and point the detector away from the Tone Generator when pulling the trigger on the detector The ultrasound produced by the Tone Generator is quite intense and can cause a Drum Head type of transmission of energy if the enclosure is a thin material you can dampen this with a rag pressed lightly against the outer side of the can being sure not to cover seams or seals Ultrasound will not pass through a solid so the leak channel must be dry as water in the air path appears as a solid to the ultrasound This is especially true when looking for leaks in automobile windshields or roof leaks The following diagrams are examples of how the tone generator is used to find leaks in various types of volumes but is by no means a complete list of its uses Tone Generators Tone Leakage y Tone leakagt Tone generator capacity for a closed volume with hard reflective surfaces a
80. nd no blocking obstructions such as baffles is approximately 1500 cubic feet and is omni directional Note Additional transmitters can be added to extend coverage Directional Application When a tone generator is placed with emissions directed towards a surface area to be tested the total volume is not a consideration but you should aim the generator at the general area being inspected Multiple tone generators can be placed SO as to cover a larger area or multiple areas One use here is for seams seals gaskets doors or window openings OPERATION AS A MICROSONIC STETHOSCOPE Pump Bearing Motor Wear Wear Wear Pistol Style Stethoscope Detector Insert the Stethoscope Module the one with the metal probe extending from the front into the recessed front of the Detector body Be sure that both connector pins line up with the receptacles and that the Module seats fully in the recess Be sure the metal probe is screwed into the front of the module only finger tight Over tightening could result in internal damage to the Stethoscope Module Sensitivity adjustments and calibration are essentially the same as described above for Leak Detector use with the following added stethoscope only adjustment If when using your stethoscope you find the unit is too sensitive the meter remains at full scale when the volume sensitivity knob is all the way down sensitivity can be reduced further by reducing the sensitivity of
81. ndicators being presented to our senses Ultrasonic testing eliminates some of these variables allowing us to make a more accurate determination of the indications perceived This section describes the majority of indicators that exist under the most common or normal operation Indications other than those covered in these instructions will require a more detailed investigation of the trap in question or disassembly The accuracy of results will improve in a direct relationship with the experience gained through continuing usage All traps appear to be discharging steam as they discharge condensate but this is only flash steam 22 STEAM TRAPS Where Are They Process Traps Typical Process Trap Application o TEAM SUPPLY CONDENSATE RETURN PROCESS OUT PROCESS IN STRAINER STEAM TRAP 53 STEAM TRAPS Where Are They Drip Trap Typical Drip Trap Application STEAM TRAPS Where are they Trace Traps Typical Trace Trap Application 55 STEAM TRAPS INVERTED BUCKET TRAP A BUCKET e The maximum pressure rating on the bucket trap should be shown on the metal tag located on the trap e The pressure rating indicated on the Tag is the maximum steam pressure the trap will handle effectively If there is more steam pressure at the trap than shown on the identifying tag you need to put in a different valve mechanism A K A pressure change assembly to allow the trap to
82. ng assembly WITHOUT WATER OR AIR PRESSURE BEFORE BURYING PIPE Find Rolled or Pinched Gaskets Cracks or Pinholes Frequently this equipment pays for itself with the first use You may also use the EFI Microsonic tool to detect leaks underground after the project is buried DETECTION METHODS During assembly a Microsonic tone generator is placed inside the pipe or other volume Vault Manhole etc this will saturate the inside area with high intensity ultrasonic sound not audible to the human ear This high intensity ultrasonic sound will find and exit any hole in the pipe or joint A hand held Microsonic Detector is then used to scan the area being tested for leaks seals gaskets cracks or pinholes When a leak is detected the operator will hear an audible indication in his headphones and will see an indication on the analog meter built into the detector It s that simple Ultrasonic testing is quick accurate and cost effective Pressurized air amp gas leaks produce turbulence with high frequency components To locate compressed air and gas leaks simply scan the test area with the hand held EFI Microsonic detector If a leak 15 present ultrasonic sound not audible to the human ear is produced This high frequency sound will be heard by the EFI detector and converted into an audible hissing sound heard through the systems headphones Simply follow it to the loudest point If it 1s difficult to discriminate the leaks location reduce the
83. ng the black plastic screwdriver which came with the detector kit At times it may be desirable to restrict outside interfering ultrasonic noises or to increase the directivity of the unit To do this slip the Rubber Focusing Extension onto the front of the Leak Detection module This also assists in picking up sounds of a small leak in inaccessible locations such as on the rear side of pipe fittings It also allows one to drag the rubber font end opening along seams and seals without creating a lot of interfering ultrasonic noise As a reminder the knob controls overall sensitivity of the detector both headset volume and the meter circuitry To obtain near repeatability of readings both the knob and the meter sensitivity settings must be the same as during previous tests As a general rule once the detector has been in use for a short period of time the meter sensitivity is seldom touched You will very quickly find a setting that is satisfactory for almost all your uses If when using your leak detector you find the unit is too sensitive the meter remains at full scale when the volume sensitivity knob is all the way down sensitivity can be reduced further by reducing the sensitivity of the Leak Detector Module itself by adjusting the potentiometer located in the module itself Use the black plastic screwdriver supplied with your kit to turn down the control through the hole on the top side of the module just forward of the red housing un
84. ng unpressurized containers involves the use of an ultrasonic sound generator and a detector matched to the same frequency When used in a closed container with walls which reflect rather than dampen noise the ultrasonic signals will pass through small leaks and can be detected This technique has been used successfully on items such as welded seams airplane compartments refrigerators automobile windows condenser tubes and large tanks Electrical Discharge The fourth type of ultrasonic noise that can be detected is generated by electrical discharges corona sparks and flashovers When an electrical spark jumps from one object to another the heated air expands rapidly and produces an airborne shock wave This effect is similar to that of thunder which accompanies a lightning stroke The strong agitation of the air produces ultrasonic noise Therefore the detection device can be used to locate electrical defects i e high voltage corona discharges arcs in cables on trolley arms carbon brushes transformers motors contactors insulators reactors distribution systems and other electrical installations subject to electrical leakage or breakdown of insulation advance of a vibration or heat signature making it very compatible Ultrasonic testing will often detect an ultrasound signature in when used to determine productive areas for the application of vibration analyses or thermographic imaging Ultrasonic test equipment is in
85. nit s analog meter Testing using a soap solution and watching for bubbles is very time consuming and will frequently miss leaks altogether if the tested area is not visible Conducting an ultrasonic leak survey The best plan is to inspect the entire plant department by department always following the same pattern However if such a program seems too daunting a plant might limit periodic inspections to one or two departments As maintenance crews become more familiar with ultrasound and inspection techniques the survey can be expanded to include the entire operation The technician aims the ultrasonic scanner directly at the part of the system under inspection and makes small cross pattern movements along all exposed sections The more sensitivity levels the instrument has the better it performs If for example a 1 in pipe is suspected of leaking the technician should wave the gun an inch or two in each direction moving parallel to the pipe until finding the leak Then the instrument s close focus adapter can be honed in on the exact location of the leak The problem may actually be in the fitting Every leak should be tagged with the location and an identification number A note should also record a description of each leak including the size The technician should double check each leak that is repaired before moving on to the next area Often new leaks are inadvertently created during the repair stage and go unnoticed because the area i
86. ns and same rotational speed Approach the bearings at the same angle touching approximately the same area on the bearing housing Compare differences of meter reading and sound quality Historical Bearing Test Use the basic procedure as outlined above in the comparative test Note meter reading and sensitivity selection on your bearing history chart Compare this reading with previous or future readings On all future readings adjust sensitivity level to the original level recorded in the bearing history chart If the meter reading has moved form the original 20 mark up to or past 100 there has been a 12 db increase Increments of 20 on the meter in the linear mode is about 3 decibels e g 20 40 3db 40 60 3db etc Note Increase of 12 db or greater indicates the bearing has entered a failure mode Lack of lubrication is usually indicated by an 8 db increase over baseline It is usually heard as a loud rushing sound If lack of lubrication is suspected after lubricating re test If readings do not go back to original levels and remain high consider that the bearing is on the way to the failure mode and recheck frequently If a vibration program already exists for bearing analysis an ultrasonic bearing monitoring program can be of assistance Ultrasound detectors can be used to aid a diagnosis The high frequency short wave characteristic of ultrasound allows the signal to be isolated so that a user can determine if a bearing has been c
87. ome steady mechanical noises These should not be confused with the erratic sizzling frying uneven and popping sound of an electrical discharge Detection Method Before beginning any inspection of mid or high voltage equipment be sure to review your plant or company s safety procedures Essentially as in generic leak detection the area of inspection is scanned using a high sensitivity setting As the direction is determined and you approach the source reduce the sensitivity until pinpointing is possible If it is not possible to remove covers or plates scan around the seams and vent slots Any potentially damaging discharges should be detected 44 SECTION 7 o TEAM TRAPS e Steam Traps and Valves explained e How to analyze them using the Ultrasonic tools e Determine good and bad traps and predict failure PREFACE Any method used to check the operating performance of steam traps requires experience on the part of the individual conducting the test The reason is that a great number of variables exist causing many different indicators being presented to our senses Ultrasonic testing eliminates some of these variables allowing us to make a more accurate determination of the indications perceived This section describes the majority of indicators that exist under the most common or normal operation Indications other than those covered in these instructions will require a more detailed investigation of the trap question
88. on of the muzzle helps pinpoint exact location of the leak As you approach the leak continuously reduce the sensitivity using the knob just forward of the trigger to enable exact pinpointing of the leak To demonstrate the approximate sound of a leak and the reaction of the meter to it hold your free hand in front of the detector and briskly rub your fingers and thumb together the resulting noise heard in the headset is from the ultrasonic noise generated by the friction at your finger tips If the meter jumps too rapidly and bangs against the full scale side of the meter it may be desirable to reduce the meter sensitivity Meter sensitivity is adjusted by inserting the adjusting tool small red screwdriver which came with the kit into the hole on the left side of the pistol body and setting the desired meter sensitivity This adjustment does not affect the detection ability of the unit only the meter sensitivity The leak detector is directional and you can follow it directly to a leak As you approach a leak point the meter may remain at full scale and or you will not be able to hear a difference in the sound level When this occurs start reducing the sensitivity to keep the meter on scale Continually reduce the sensitivity until the leak point is pinpointed If it is still too sensitive you can additionally reduce the sensitivity by turning the module sensitivity adjustment located on the top of the black module itself counterclockwise usi
89. onents vibrates or rings by this repetitive impact The sound produced is observed as an increase in amplitude in the monitored ultrasonic frequencies of the bearing Brinelling of bearing surfaces will produce a similar increase in amplitude due to the flattening process as the balls get out of round These flat spots also produce a repetitive ringing that is detected as an increase in amplitude of monitored frequencies The ultrasonic frequencies detected by the system are reproduced as audible sounds This signal can greatly assist a user in determining bearing problems When listening it is recommended that a user become familiar with the sounds of a good bearing often heard as a rushing or hissing noise Crackling or rough sounds indicate a bearing in the failure stage In certain cases a damaged ball can be heard as a clicking sound whereas a high intensity uniform rough sound may indicate a damaged race or uniform ball damage Loud rushing sounds similar to the rushing sound of a good bearing only slightly rougher can indicate lack or lubrication Pro Active amp Predictive Maintenance Ultrasonic Technology Picks Up what may be future failure Mechanical problems can be detected amp avoided using ultrasound Preventative Maintenance Ultrasonic scanning instruments are fast becoming standard tools for preventative maintenance programs in the food processing industry The ability to use ultrasound tools to pinpoint and repair f
90. or This device is placed in a cabin tank or container where it floods the area with an intense ultrasonic signal The generated ultrasound will deflect off solid seals but will flow through a leak path Some of the most common areas for ultrasonic inspection include COMPRESSED AIR amp BRAKE SYSTEMS CNG amp LNG GAS SYSTEMS VACUUM SYSTEMS ENGINE INTAKE SYSTEM LEAKS EXHAUST SYSTEM LEAKS ENGINE INTERNAL DIAGNOSTICS DRIVE LINE DIAGNOSTICS BEARINGS PUMPS amp ELECTRIC MOTORS FUEL TANKS WIND NOISE amp WATER LEAKS amp TRUNK COMPARTMENT LEAKS DOOR WINDOW FLOOR amp ROOF SEALS HYDROLICS FUEL INJECTORS DRIVE BELTS Detection Methods Pressurized air gas amp fluid leaks produce turbulence with high frequency components To locate air gas or fluid leaks under pressure simply scan the test area with the hand held EFI Microsonic detector If a leak is present ultrasonic sound not audible to the human ear is produced This high frequency sound will be heard by the EFI detector and converted into an audible hissing sound heard through the systems headphones Simply follow it to the loudest point If 1t is difficult to discriminate the leaks location reduce the sensitivity and continue to follow to the loudest point REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 95 MARINE ULTRASONIC INSPECTION DESCRIPTION Ultrasonic inspection can be used in practically every phase of the maritime industry There are appli
91. or example recently a small manufacturing company considering the purchase of a second larger air compressor ordered an audit of its compressed air system The findings showed that more than 75 000 of the 100 000 the company had been spending annually to run its primary air compressor was being wasted because of air leaks uncontrolled demand and poor applications Installing a larger air compressor would only have compounded the problem while increasing energy consumption What the company really needed was a program to educate its maintenance staff about testing procedures and technologies that would eliminate waste and allow the plant to run more efficiently Learning how to conduct an in plant air leak survey is simple A variety of tools using airborne ultrasound technology allow inspectors to detect deteriorating components and repair them before they fail The results are startling and the impact on the company s bottom line will impress top management 78 What causes air leaks Audits generally turn up few leaks in the overhead distribution piping although such leaks can easily be detected from the ground with the right equipment Corrosion also is not a common cause of leaks The real problems are usually at ground level in hoses hose connections and fittings quick couplers filters regulators and lubricators Air cylinders often leak around the rod seals or piston packing Piston packing leaks are apparent at the cylinder
92. orrectly diagnosed as failing At times there can be false signals generated by equipment connected to a particular bearing By adjusting the sensitivity and listening to the sound it can be determined whether it is the bearing a rotor or something else that is the root of the problem 38 The ability to hear what is going on can prove very important Ultrasound detectors work well on slow speed bearings In some extreme cases just being able to hear some movement of a bearing through a well greased casing could provide information about potential failure The sound might not have enough energy to stimulate classic vibration accelerometers but will be heard via ultrasonic detectors Sometimes there are so many bearings in a plant that not every piece of equipment can be checked routinely by a limited staff of trained technicians Since ultrasound detectors require little training a technician or the machine operator can determine potential bearing problems and notify the vibration technician for follow up Gears Pumps amp Motors Inspection OPERATION AS A MICROSONIC STETHOSCOPE Insert the Stethoscope Module the one with the metal probe extending from the front into the recessed front of the Pistol Detector body Be sure that both connector pins line up with the receptacles and that the Module seats fully in the recess Be sure the metal probe is screwed into the front of the module only finger tight Over tightening could r
93. p before damage to armature Monitor pump internal components In addition since ultrasound is a high frequency short wave signal it is possible to filter out stray confusing background noises and focuses on the specific item to be inspected Basic inspection methods are extremely simple and require very little training In addition ultrasonic testing works extremely well with vibration technology In fact the two technologies complement each other and enhance any PDM Predictive Maintenance program How Ultrasound Bearing and Mechanical Inspection Works Mechanical movements produce a wide spectrum of sound By focusing on a narrow band of high frequencies the Microsonic unit detects subtle changes in amplitude and sound quality It then heterodynes these normally undetectable sounds down into the audible range where they are observed on a meter for trending and comparison purposes and heard through headphones Based on research by NASA it was established that ultrasonic monitoring provides early warning of bearing failure Various stages of bearing failure have been established An 8 dB gain over baseline indicates pre failure or lack of lubrication A 12 dB increase establishes the very beginning of the failure mode A 16 dB gain indicates advanced failure condition while a 35 50 dB gain warns of catastrophic failure Ultrasonic Bearing Inspection Method There are two basic methods for ultrasonic bearing monitoring comparative and his
94. properly will open and close with a distinct cycle 2 HEAVY LOAD Trap will discharge condensate continuously This is usually observed at the startup of mu equipment If the trap does not catch up with 20 40 60 the load and commence intermittent E discharge this is usually an indication that the trap is undersize for the application Undersize or continuously discharging under heavy load will register high on the scale but with some back and forth movement of the meter needle MIChOSONIC 3 CHATTERING OR RAPID CYCLE Wear of the disc valve amp seat will cause the trap to operate with a rapid cycle resulting in considerable steam loss The trap should close between cycles for a period of at least 15 seconds Any shorter period of closure indicates the need for replacement 4 LEAKING STEAM 10 AO Ni As a result of wear the disc valve will not seal SU properly allowing steam to leak through the seat The indicator does not return to 0 or MICRO level of ambient noise between cycles indicates leakage JNIC DE TEC 63 STEAM TRAPS Ale ven Ts Place probe on trap as shown Air Tw Alr vent c4 ROBE c 64 STEAM TRAPS FREE FLOAT TRAP A Place probe on trap as shown Air vent BALL FLOAT STEAM TRAPS are mechanical Traps and operate on the difference in density between steam and condensate Con
95. r amp gas leaks produce turbulence with high frequency components To locate compressed air and gas leaks simply scan the test area with the hand held EFI Microsonic detector If a leak is present ultrasonic sound not audible to the human ear is produced This high frequency sound will be heard by the EFI detector and converted into an audible hissing sound heard through the systems headphones Simply follow it to the loudest point If it 1s difficult to discriminate the leaks location reduce the sensitivity and continue to follow to the loudest point REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 98 Heat Exchangers Boilers Condensers DESCRIPTION Leak Detection of heat exchangers boilers and condensers most often involves inspection of three generic areas tubes tube sheets and housings The Microsonic detection unit can be used to detect leaks three ways pressure leaks vacuum leaks or by utilizing a unique Tone transmission method While it may be necessary to take a unit off line to inspect for leaks with ultrasound it is often possible to perform an inspection while on line or at partial load How Ultrasonic Leak Detection Works During a leak the fluid will flow from high pressure to low pressure producing a turbulent flow at the leak site This turbulence has strong ultrasonic components which are sensed and translated via heterodyning into the audible range where they are heard in headphones and seen as int
96. r greasing is as destructive as not greasing a bearing 40 Air Compressor Inspection DESCRIPTION Drive Belts Compressors are the heart of any compressed gas system Routine inspection and maintenance can prevent unplanned downtime Although any type of compressor can be inspected ultrasonically the most common application centers on larger reciprocating types Specifically valve function in these compressors is critical Minor valve leaks can rapidly lead to large leaks which can effect production Internal impact on plant safety Loose Components Alignment How Ultrasonic Compressor Inspection Works As with any mechanical movement there is a normal operation and a deviation In the case of valves normal function is the typical open close movement Ultrasonically this will be observed as a rhythmic movement When valve movement changes due to leakage or sticking the sound pattern changes Each condition has ultrasonic components that can be sensed and monitored by the ultrasonic detection unit Due to the short wave high frequency nature of ultrasound the sounds produced by a compressor valve can be isolated which provides a clear test result Detection Method For the contact method touch the valve with the contact probe and reduce the sensitivity until it is possible to obtain a meter swing around mid line and hear the valve open close movement When testing be sure to compare similar val
97. r stages of failure Since high frequency vibrations do not radiate as much as low frequency vibrations use of the Microsonic Stethoscope allows you to more readily screen out some sounds and pay particular attention to others Internal flow can be heard with the Stethoscope to detect turbulence or blockage in lines or process flow It is easy to tell if a valve has shut completely is leaking or bypassing You can hear the action of the valve and the flow As the valve closes completely flow ceases If the valve stops moving as if closed and flow is still heard the valve has not seated and sealed properly The Ultrasonic Stethoscope is the tool of choice for detecting bad or malfunctioning steam traps When using a grease gun to lubricate bearings the stethoscope should be placed on the housing in the vicinity of the bearing as the grease is added As you add grease the sound will continuously diminish until the optimum grease point is reached adding more grease will cause the sound to increase and should be avoided as over greasing is as destructive as not greasing a bearing The Magnetic Stethoscope Module in combination with the Holster makes this operation easier for a person working alone Tubular Style Stethoscope Finding mechanical troubles with the Tubular Style Stethoscope is the same as when using the Pistol Style Stethoscope The difference is that the tubular units do not have a meter nor do they have plug in front end unit
98. rly sized traps relieve the condensate react quickly to changes in load and trap the steam while allowing air and other non condensable gases to escape he Says Finding Malfunctioning Traps As with any mechanical device a steam trap can malfunction If the steam trap fails closed says Banyacski the device that should be draining will flood the heat transfer process will stop and whatever product is being produced will no longer be up to the required quality standards If the trap fails open there will be a waste of energy steam will not be completely consumed or condensed in the exchanger and steam will blow through Banyacski notes that a plume of steam escaping from some part of the condensate return system signals such a condition Banyacski ads that it is 46 difficult to determine whether a steam trap has failed just partially open indicating a slow leak and a developing failure He continues Such a failure could persist for quite some time without any outward sign Therefore a maintenance person should make periodic surveys of the installed steam traps Banyacski emphasizes that steam blowing through a trap indicates that the trap needs to be repaired or replaced Trap Inspection Methods Echoing Banyacski Kevin Loken manufacturers representative and distributor with Kelly Equipment Milwaukee Wisconsin says Oftentimes a misapplied steam trap too small the wrong design will malfunction According
99. rtified that these instruments meet or exceed the Electronics For Industry Inc standards as outlined in the Electronics For Industry Inc standard test and calibration procedures and all applicable ISO 9000 and CE requirements All leak detection equipment meet the requirements of ASTME E1002 96 as currently published All equipment used to calibrate the ultrasonic equipment is traceable to NBS and is traceable to QEC Standard Meter QE 579 s n 5225 Prepared and attested to this date by George A Harris President SECTION 3 INTRODUCTION TO ULTRASOUND What is Ultrasound Sound has been defined as vibration of an air column to which a human ear would respond Ultrasound is those frequencies that are above human hearing Humans can usually begin to hear low frequency sound at about 30 Hertz cycles per second This is comparable to the low bass frequencies in a good music system The upper range for high frequency hearing is usually in the neighborhood of 15 000 20 000 Hertz or 15 to 20 Kilohertz Near either end of this range hearing sensitivity has decreased significantly sound has to be louder to be heard Maximum human hearing sensitivity is in the 2 000 to 4 000 Hertz range which includes most speech frequencies As children age toward adulthood they gradually lose some hearing sensitivity Deterioration generally affects the high frequency hearing ability most and affects males sooner than females The discrimination might r
100. s they are complete and self contained The rotary control on the top of the unit is the on off and sensitivity control After plugging a headset into the receptacle on the rear of the detector you then rotate the control forward to turn it on and set the sensitivity and volume level Now the search is the same as described above for the Pistol Style Stethoscope Be sure to turn the unit off when not in use to conserve battery power The 9 Volt battery is located under the cover toward the rear of the detector unit Unscrew the two slotted head machine screws to access the battery An additional sensitivity control us located under the battery to further reduce sensitivity of you find the unit too sensitive SECTION 2 EFI DETECTION KITS GENERAL DESCRIPTION OF THE KITS DESCRIPTION pictures follow the description pages In general an EFI pistol type detection kit is comprised of the El 701 detector body a plug in probe either LM 1 or SM 1 and a headset either a lightweight headset or deluxe headset customers choice The tubular detectors shown below consist of the detector body and headset DELUXE HEADSET The deluxe headset is designed to aid in reduction of outside noises The headband is usually worn over the top of the head but may be worn at the back of the head to help accommodate a hardhat The earmuffs cover the ear and fit snugly against the head to block interfering sound leakage LIGHTWEIGHT HEADSET The lightweight heads
101. s in the tote bags put on the headphones and placed the ultrasonic detector near the sack It was amazing You could actually hear the insects crunching on the peas Joe Coencas Contributing Editor Plant management 3l Comparative amp Historic Testing Mechanical There are two basic procedures of testing for bearing problems comparative and historical The comparative method involves testing two or more similar bearings and comparing potential differences Historicaltesting requires monitoring a specific bearing over a period of time to establish its history By analyzing bearing history wear patterns at ultrasonic frequencies become obvious which allows for early detection and correction of bearing problems Comparative Test Use the contact stethoscope module Select a test spot on the bearing housing and mark it for future reference Touch that spot with the contact probe In ultrasonic sensing the more mediums or materials ultrasound has to travel through the less accurate the reading will be Therefore be sure the contact probe is actually touching the bearing housing If this is difficult touch a grease fitting or touch as close to the bearing as possible For consistency always approach the test spot at the same angle Reduce sensitivity until the meter reads 20 Listen to the bearing sound through headphones to hear the quality of the signal for proper interpretation Select same type bearings under similar load conditio
102. s not retested Using confirmation and shielding techniques such as sealing always pays off when the entire connection is checked one final time REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 101 MILITARY VEHICLE GROUND SUPPORT ULTRASONIC INSPECTION DESCRIPTION The most common areas for ultrasonic inspection in ground and air transportation are air water gas leaks into personnel amp equipment compartments pressurized systems leaks air brakes motors pumps amp bearings Until the advent of ultrasound liquid and gas intrusion detection involved many hours of trial and error with a water hose and flashlight Often applying a liquid under pressure or listening with a conventional stethoscope for a pressure leak required two people for many hours Air brake leaks exhaust and intake leaks can take hours to locate using conventional soap and water bubble testing Not only can service facilities benefit from Ultrasonic Inspection so can Quality Assurance departments by providing highly portable fast accurate and simple testing How Ultrasonic Detection Works Compressed gases when leaking produce a turbulent flow with strong ultrasonic components By scanning fittings a leak will be heard as a distinct hiss Due to the high frequency short wave nature of ultrasound the sound will be loudest at its point of origin The Microsonic unit translates the ultrasonic leak sign
103. sound in the 40 kilohertz region These mechanisms are 1 Turbulent fluid flow 2 Liquid movement 3 Mechanical movement 4 Sound generators 5 Electrical discharge Turbulent Flow Sometimes called sonic or choked flow turbulent flow is the most widely recognized source of ultrasonic vibrations Turbulent flow occurs with any fluid whether a liquid or a gas This type of flow is one of the three basic flow modes Laminar and molecular are the other two Of the three however only the turbulent flow of a fluid across a pressure boundary creates acoustic waves These waves can be transmitted through the medium of the fluid itself through the containment structure or through the air surrounding the containment structure Thus depending upon the situation turbulent flow can be detected in a variety of ways Turbulent flow often occurs through holes with a diameter of 015 inches to 0005 inches It is generally assumed that the smallest detectable flow through leaks this size is 1 x 10 standard cc sec a rate equivalent to a pound of Freon leaking out of a container every 3 months Besides instrument sensitivity two other controllable factors viscosity and velocity can improve test results Lower viscosity fluids tend to create greater turbulent energy and as a result pressurization with a gas like helium may allow the location of leaks which could not be found with air In 85 the same way great velocity or its complement a gr
104. ss a pressure boundary create strong ultrasonic signals as they burst and reform Bubbles which are often too small to be seen can be heard easily ultrasonically Soap and water will not work for this technique Soap or detergent solutions form a great number of bubbles when applied This makes it difficult to distinguish real from apparent leaks In addition soap solutions form large rather than small bubbles and as a result they do not produce much ultrasonic energy nor do they burst very often For these and a number of other reasons soap or detergent solutions have been banned by a number of regulatory agencies such as ASTM and ASME for any leak detection use Mechanical Movement Another widely used source of ultrasonic energy results from contact between metal parts and stress Stressed material which results in stretching shearing abrading or other types of deformation releases high levels of ultrasonic energy Ultrasonic sound resulting from friction is often used to monitor machines to prevent shutdowns and predict maintenance needs Examples of problems that are easy to detect are Bearings with pits cracked races loose parts lubrication failure misalignment malfunctioning valves or gears By detecting defects such as insufficient oil film worn 86 bearings misalignment or defective gears before significant increases in vibration or temperature incipient failures can be prevented Sound Generation A technique for testi
105. ster a very slight modulating R movement of the indicator at the bottom end of the scale Note Under extremely light load conditions at times there may be no apparent movement of the pointer observed which is normal 2 MEDIUM LOAD 5 pa Under medium load conditions the wwii yy modulating pointer will register higher the scale MICROSONKDETECIOH 3 HEAVY LOAD Indicator will register heavy condensate load high on the scale indicating the trap is 20 10 60 p working at maximum capacity This wow condition is usually observed at startup of equipment and the trap should catch up with the load and the modulating pointer will begin to move down the scale If the pointer remains at the top of the scale this would be an indication of under sizing 10 MICKUSONIC DII be TOR 67 STEAM TRAPS THERMOSTTIC TRAP A Place probe on trap as shown STEAM TRAPS THERMOSTATIC TRAP B THERMOSTATIC TRAPS BIMETALLIC THERMOSTATIC TRAP 5 Bimatalic Elements Hot or Subcooled Liguri Condensate Sieam or Condensale inet liquid Condensate amp Flash Outlet THERMOSTATIC TRAP Cold condensate during startup drains through the trap As temperatures reach 10 to 30 degrees Fahrenheit of saturation the trap closes During operation thermostatic traps find an equilibrium point to drain condensate which is approximately 10 to 30 degrees below saturation at a
106. systems that cause your compressor to run and run Continuously running compressors means wasted electricity and wasted dollars Continuously running compressors means replacing compressors before their time Continuously running compressors means you are not getting the air or vacuum to the tools that it is supposed to feed which means additional wear on these tools or machines and loss of production time Easily pinpoint these leaks as you walk through your plant Take the Microsonic Detector with you and scan the plant as you walk Make notes of the leaks and then when there is time available you know exactly where to send the repair person Over a period of time you will clean up your plants leaks and save many dollars Leaks in Pneumatic Controls and their lines means your machinery or process is not working as it was designed Pinpoint these leaks Pressure or Vacuum and get the process working efficiently again Any Gas or Vapor The Microsonic Detectors hear the sound of a leak It does not matter what is leaking any gas of vapor Compressed air steam oxygen nitrogen freon any gas or vapor Ix i 7m i 4 LS mm 32 Aircraft Pressurization leaks Pitot Static System leaks Instrument air or suction leaks leaks around the instrument faces oxygen system leaks as well as water leaks into the cabin or the baggage compartment or the avionics area Pinpoint and stop the water incurs
107. te capacity applications whereas a model 881 3 4 bucket trap for 15 psig steam will utilize a 1 4 orifice The differences in potential steam loss between the two are significant Therefore we have tried to be very conservative when assigning the orifice size in the table below The actual dollar loss may be significantly different depending upon the specific model of the trap The orifice sizes in the table below are referenced from the following Armstrong model numbers 1 2 pipe size Model 881 3 4 pipe size Model 882 1 pipe size Model 883 Order Armstrong Bulletin 301 H which contains a complete guide to the orifice sizes in the different Armstrong bucket traps Assigned orifice sizes employed in the traps below when PIPE SIZE under the differential steam pressure shown Dollar 22 32 40 48 65 41 Loss Month Dollar 34 50 63 76 65 60 NEN GEM po Dollar 86 129 162 194 145 199 Loss Month Pressure Trap 75 psig 100 psig 125 psig 150 psig 200 psig 250 psig Assigned orifice sizes employed in the traps below when PIPE SIZE under the differential steam pressure shown Dollar 37 47 57 53 68 72 Loss Month 34 Dollar 57 73 89 67 87 84 Loss Month Dollar 185 187 229 206 197 244 Loss Month 74 STEAM TRAP LOSS CALCULATIONS Modified Napier Formula PI R2 X SP X 51 42 X F O 8760 1000 X cost of steam 1000 Ibs Dollars Lost Per Year Per Trap 51
108. te within their working range without any adjustment or change of valve size Being frozen does not damage them On startup air amp cool condensate reach the trap passing up the inlet orifice F The disc C is lifted until it is held against the boss in the top cap Air and condensate flow radially outwards from the center of the disc into the space between the seat rings and E and are discharged through the outlet passage G 61 STEAM TRAPS BASIC THERMODYNAMIC TRAP OPERATION NORMAL LOAD NOTE Background noise level 0 1 CLOSED NO DISCHARGE M a 60 B0 100 inii NS 9 MICRH WNSONIC DETECTOH fa 4 Indicator at 0 on scale Disc valve closed on seat shows disc valve closed 2 OPEN DISCHARGING CONDENSATE Te u i i TM Pos 100 MIChUSONICIOE TEL TOH 18 eum Indicator rises on scale to Disc up valve open show trap discharging condensate 3 FAILED OPEN BLOWING LIVE STEAM 20 40 60 7 i ul Lf i i Pag i Indicator pegs on scale along Worn disc and seat with high pitched sound of steam passing through open valve seat 62 STEAM TRAPS THERMODYNAMIC TRAP DETAILED THERMODYNAMIC TRAP OPERATION 1 LIGHT TO MEDIUM LOAD Trap operates with intermittent cycle Length of cycle will vary in accordance with the condensate load A T D trap functioning
109. termine if it is hot or cold Place a hand near the trap If the trap is cold the problem could be a plugged strainer upstream or the trap outlet may be plugged with dirt In an inverted bucket type the bucket may have come unhooked In the float and the thermostatic type the thermostatic element may have failed shut or the float may be jammed or collapsed The disc may be jammed in a disc trap Under any of these conditions no sound will be heard with the ultrasonic tool If the trap is hot place the probe of the tool against the trap near the discharge side A continuous rushing sound suggests that the trap has malfunctioned and is discharging live steam continuously A properly operating inverted bucket should discharge intermittently as should a properly operating disc trap which will discharge 6 to 12 times per minute The discharge of live steam in a float and thermostatic trap is evidenced by a higher than normal noise level and sound pitch These are but a few general guidelines for testing steam traps with the ultrasonic tools As with any type of testing the test instrument only 49 provides evidence which must be evaluated by the user As the users experience increases so will the effectiveness of any testing program Valves ULTRASONIC INSPECTION OF VALVES Leak Detection Method Inspection methods vary depending on the type of valve Therefore the primary rule is to know the details of your system for example the way a sp
110. that technicians who use ultrasonic detectors on a daily basis can achieve accuracy that exceeds 98 And regarding frequency of inspections he recommends that process components of equipment as well as drip main steam traps should be checked twice a year He suggests that heating steam traps in facilities that use steam for space heating should be tested annually He also stresses the importance of instituting a reporting system to keep tabs on the location type size capacity and condition of all traps in a steam system 47 Creating A Maintenance Program Why go through the hard work of setting up a maintenance program for steam traps Loken supplies the answer A steam trap maintenance management program can pay for itself in less than a year And the savings will multiply as the years pass When valves or steam traps leak or fail it can be extremely costly in terms of product quality safety and energy loss Valve operation effects the way fluids Will flow through a system There are great differences in the way particular valves and steam traps work Ultrasonic testing makes it easy to adjust for these differences and readily determine operating conditions while valves and traps are on line How Ultrasonic Leak Detection works As fluid moves from the high pressure side of a valve through the seat to the low pressure side it produces turbulence This turbulence generates ultrasound which is detected by the ultrasonic probe
111. thoscope to listen at the bearing housing and begin pumping grease with your grease gun As you add grease the sound diminishes at the optimum point the bearing is quietest as you add still more you Will hear the sound begin to increase stop you have the optimum grease For ease of use we offer a magnetically positioned transducer to leave both hands free while using your grease gun Leaking or Bypassing Valves How often have you turned off a valve to work downstream and when you opened the system downstream you found the valve had not shut off fully Use the Microsonic Stethoscope to listen at the valve as you shut it off No noise itis off Still hear noise it did not shut off fully and you are hearing flow do not open the system downstream ES Prevent chemical spills Busses The Microsonic Detection Tools have many uses in Bus maintenance and repair Air brake system leaks are readily detected and heard Pneumatic system leaks or mal functions are easy to trouble shoot Air conditioning problems and leaks are readily found Tire and valve stem leaks are quickly located and pinpointed Water leaks around the windows door and baggage compartment seals are easily found and repaired and re checked using the Tone Generator a water test is never needed Pumps Are the valves opening and closing as they should Is there cavitation Can you hear air in the chambers or lines Is the ES pump running as smoothly as it s
112. til the meter remains on scale or until the desired sensitivity Is set Tubular Style Detector Finding leaks with the Tubular Style detector is the same as when using the Pistol Style detectors The difference is that the tubular units do not have a meter nor do they have plug in front end units they are complete and self contained The rotary control on the top of the unit is the on off and sensitivity control After plugging a headset into the receptacle on the rear of the detector you then rotate the control forward to turn it on and set the sensitivity and volume level Now the search is the same as described above Be sure to turn the unit off when not in use to conserve battery power The 9 Volt battery is located under the cover toward the rear of the detector unit Unscrew the two slotted head machine screws to access the battery TONE GENERATOR USE To locate openings or leaks in systems not under pressure or vacuum such as wind or water leaks in vehicles leaks around doors windows or roofs of buildings or leaks in vessels chambers containers or volumes use the Tone Generator The Tone Generator produces high intensity ultrasonic energy which is heard as a tone by your ultrasonic detector Ultrasonic sound like all sound will not penetrate a solid but will find its way through openings cracks and crevices The Tone Generator should be placed inside the enclosure The interior becomes filled with high frequency sou
113. tions for blow of lowered the demand an estimated 1035 cfm on the first shift 570 cfm on the second shift and 475 cfm on the third shift and Saturdays Blow off application improvements saved 64 933 year These three major areas of improvement accounted for 154 245 of the system s operating cost How to conduct an air leak survey All operating equipment should be checked every six months The best plan is to inspect the entire plant department by department always following the same pattern However if such a program seems too daunting a plant might limit periodic inspections to one or two departments As maintenance crews become more familiar with ultrasound and inspection techniques the survey can be expanded to include the entire operation 80 Air leak inspections can be conducted with the equipment on or off As a rule technicians begin by determining at what kinds of loads the air compressors are operating They use the ultrasonic tools to establish sound patterns of properly operating equipment It is important to slowly scan the entire air line system The technician aims the ultrasonic detector directly at the part of the machine under inspection and makes small cross pattern movements along all exposed sections The more sensitivity levels the instrument has the better it performs If for example a one inch pipe is suspected of leaking the technician should wave the gun an inch or two in each direction moving paralle
114. to 36 Tubular Style 6 1 oz Aluminum 8 5 1 25 1 9V Detector Deluxe Headset 9 20z Molded Plastic DH 1 Light Weight 0 7 oz Headset SH 1 Molded Plastic Large Carrying 1 5 Lbs Cordura 14 Case CC 800 Case Operating frequency 35 KHz to 45 KHz Operating Range 40 Feet Sensitivity Hear pressure leaks of 001 3 psi Intrinsically Safe Class 1 Division 1 Groups B C amp D Output Audio Visual 15 Safety Ratings The El 300 El 500 and TG 2 have been rated intrinsically safe and designed to meet FM approval for Class 1 Division 1 Groups B C amp D when used with Standard carbon zinc batteries The 701 Pistol style has been rated intrinsically safe and designed to meet FM approval for Class 1 Division 1 Groups C amp D when used with standard carbon zinc batteries EFI Detectors have been in the market over 45 years and are designed to withstand a rigorous Industrial environment Warranty and Repair Service Your Microsonic Detection Kit is manufactured with high quality components and workmanship and is warranted to be free from failure for a period of one year from date of purchase battery excluded This warranty shall not cover or apply 1 to any failure caused by abuse 2 if it has been tampered with or 3 if repairs have been attempted by anyone other than Electronics For Industry Inc trained service personnel Many units returned to the factory for repair have only needed a fresh
115. to Loken ultrasonic infrared temperature measurements and visual inspection have proven useful to maintenance personnel in checking for malfunctioning steam traps Of the three Loken says that ultrasound is the most reliable He points out that visual inspection requires an inspector to let a steam trap discharge into the atmosphere However doing that changes the parameters of the closed system and therefore can be unreliable Loken also says that there are enough variables in the system backpressure for example so that temperature is not the most reliable indicator either He recognizes however that portable infrared thermometers provide close estimations of pressures on valves traps and coil heaters And he notes that these devices are also useful for spotting conditions such as heat loss the need for insulation overheating overloads and cooling failures Thus he recommends that an infrared thermometer be used along with ultrasound Agreeing with Banyacski Loken says that traps that have failed completely open are easy to detect but he points out that the object is to find failing traps before they fail completely Ultrasonic testing can do that In essence using an ultrasonic instrument is like putting the inspector inside the steam trap and piping system allowing him to detect a leaking steam trap Loken says Ultrasonic detectors translate ultrasonic emissions into sounds the human ear can hear Loken claims
116. torical In order to trouble shoot bearings or to establish a baseline it is necessary to compare similar bearings for potential differences in amplitude and sound quality To do this make a reference point on a bearing housing or use the grease fitting using the stethoscope module make contact with the machinery and reduce the sensitivity until the bearing reads 20 on the meter Then compare this base reading to other similar bearings A failing bearing will show an 8 dB gain Once a series of bearings have been tested and a base line set data 1s recorded and then compared to future readings for historical trending and analysis REMEMBER TO FIX IT FIRST YOU HAVE TO FIND IT 91 COMPRESSORS PRESSURE amp VACUUM SYSTEM ULTRASONIC INSPECTION DESCRIPTION Compressors are the heart of any compressed gas system Routine inspection and maintenance can prevent unplanned downtime Although any type of compressor can be inspected ultrasonically the most common application centers on larger reciprocating types Specifically valve function in these compressors is critical Minor valve leaks can rapidly lead to large leaks which can effect production and impact on plant safety How Ultrasonic Compressor Inspection Works As with any mechanical movement there is a normal operation and a deviation In the case of valves normal function is the typical open close movement Ultrasonically this will be observed as a rhythmic movement
117. ts leaks in compressed air and vacuum systems prevents over lubrication and can be used on high as well as low speed bearings In addition since ultrasound is a high frequency short wave signal it is possible to filter out stray confusing background noises and focuses on the specific item to be inspected Basic inspection methods are extremely simple and require very little training In addition ultrasonic testing works extremely well with vibration technology In fact the two technologies complement each other and enhance any PDM Predictive Maintenance program Some common areas for ultrasonic inspection in the industrial amp commercial environment COMPRESSED AIR GAS SYSTEMS FOR LEAKS VACUUM SYSTEMS FOR LEAKS BEARINGS FOR WEAR ELECTRIC MOTORS FOR BEARING WEAR AND ELECTRICAL SHORTING PUMPS FOR INTERNAL WEAR ELECTRIC PANELS FOR ARCING AND SHORTING HYDROLICS FOR INTERNAL LEAKAGE WIRE ROPE FOR EXTERNAL WEAR amp FRAY DRIVE BELTS FOR CRACKS AND WEAR with equipment in operation amp belt guards in place ENCLOSED AREAS ROOMS CONTAINERS VAULTS TANKS ETC e VALVES GASKETS SEALS How Ultrasonic Detection Works Compressed gases when leaking produce a turbulent flow with strong ultrasonic components By scanning fittings a leak will be heard as a distinct hiss Due to the high frequency short wave nature of ultrasound the sound will be loudest at its point of origin The Microsonic unit translates the ultrasonic leak si
118. uch as arcing tracking or coronas are all potential for equipment failure In addition the problems of RFI and TVI impact on our valuable communication networks All these conditions produce ultrasound and are detected with the Microsonic detection unit Bushing go gt Ceramic Stress Tracking How Ultrasonic Electrical Detection Works Arcing tracking and corona all produce some form of ionization which disturbs the air molecules around it The Microsonic unit detects the high frequency noise produced by this effect and translates it via heterodyning down into the audible ranges The specific sound quality of each type of emission is heard in headphones while the intensity of the signal is observed on a meter Normally electrical equipment should be silent although some may produce a constant 60 cycle hum or some steady mechanical noises These should not be confused with the erratic sizzling frying uneven and popping sound of an electrical discharge Detection Method Before beginning any inspection of mid or high voltage equipment be sure to review your plant or company s safety procedures Essentially as in generic leak detection the area of inspection is scanned using a high sensitivity level As the discriminate direction reduce the sensitivity until this is possible If it is not possible to remove covers or plates scan around the seams and vent slots Any potentially damaging discharges should be detected REMEMBER TO
119. ucks as shown Actual dollar loss may be more or less than shown Pressure 2 5 10 15 25 100 125 150 50 psig 75 psig Trap psig psig psig psig psig psig LOSS FROM AIR VENT The air vents in all the F amp T traps generally utilize a 1 4 discharge orifice Dollar 22 32 4 48 65 105 147 187 6229 6270 Loss Month Assigned orifice size utilized by the mechanism assembly per sizes and differential pressures shown Dollar 114 wsne 5 16 5 16 5 16 1 4 p3n6 3 16 Dollar 1 1 2 ES 5 16 7 32 7 32 5 32 5 32 5 32 Ponar 57 685 6105 129 6101 881 112 89 105 Loss Month j 15 32 n 2 1 2 1 2 1 2 1 2 i 7 16 7 16 5 16 5 16 55 16 Dollar 86 129 8162 194 1 228 324 516 1 294 357 421 Loss Month 73 DOLLAR LOSS TABLE FOR INVERTED BUCKET TRAPS Steam Cost 6 1000 Inverted bucket traps are generally found on higher pressure steam systems However many like the long lasting characteristics of the trap and install them where one might normally find float and thermostatic traps Due to the many different orifice sizes in the many different models of inverted bucket traps the guide below is a really rough estimate of the potential steam loss For example An Armstrong model 883 3 4 bucket trap made for 15 psig steam will utilize a 1 2 orifice for high condensa
120. ves to each other i e intake to intake exhaust to exhaust and under the same conditions i e idling vs working For additional localization use the leak detection module with rubber focusing extension 4 SECTION 6 ELECTRICAL Electrical inspection e OVERVIEW OF ELECTICAL EQUIPMENT AND ULTRASONICS e OVERVIEW OF EQUIPMENT FOR HIGH VOLTAGE INSPECTION e ELECTRICAL DETECTION METHODS Overview of Electrical Inspection Track Corona Discharges with Ultrasonic Detector By Stan Bullock Manager Ultrasound detectors perfectly complement infrared instruments for the routine examination of electrical equipment While infrared inspections allow operators to detect light that the eye cannot see ultrasound allows them to detect sounds that the ear cannot hear Corona arcing and tracking which may not show up on infrared inspections are revealed by ultrasound Inspectors at Midwest Electrical Testing amp Maintenance now pack an ultrasonic detector to scan primary power on all systems they inspect A person with no experience can learn to use the tool in about an hour However it takes more experience to be able to identify individual sounds Usually the operator begins an inspection by fully opening the scale and broadly scanning the equipment If a noise is detected the operator uses the tuning and directional capabilities of the instrument to home in on the source Detect tracking on arresters In surveys performed for one
121. wear begins in machinery ultrasonic sound from increasing friction is building up long before the unaided ear can hear it The Stethoscope is valuable because of this It forewarns you The repair or maintenance can be carried out at a more convenient time rather than waiting for failure that always occurs at the most inopportune time Furthermore damage is often more severe during later stages of failure Since high frequency vibrations do not radiate as much as low frequency vibrations use of the Microsonic Stethoscope allows you to more readily screen out some sounds and pay particular attention to others Internal flow can be heard with the Stethoscope to detect turbulence or blockage in lines or process flow It is easy to tell if a valve has shut completely is leaking or bypassing You can hear the action of the valve and the flow As the valve closes completely flow ceases If the valve stops moving as if closed and flow is still heard the valve has not seated and sealed properly The Ultrasonic Stethoscope is the tool of choice for detecting bad or malfunctioning steam traps OVER GREASING DESTROYS BEARINGS When using a grease gun to lubricate bearings the stethoscope should be placed on the housing in the vicinity of the bearing as the grease is added As you add grease the sound will continuously diminish until the optimum grease point is reached adding more grease will cause the sound to increase and should be avoided as ove

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